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HASFK-2
HIGH ALTITUDE CONVERSION KIT(S)
INSTALLATION INSTRUCTIONS
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.
RECOGNIZE THIS SYMBOL
AS A SAFETY PRECAUTION
DESCRIPTION
This kit contains the appropriate burner orifices, and pressure switch for the application of 90% furnaces in installations above their maximum (as shipped) rated altitudes. This
kit is not applicable in Canada. Parts apply as shown in the
table below.
Above 7,000 Feet
Natural Gas
Orifices
B2589907 (#49) B2589908 (#56)
Propane Gas
Orifices
Pressure
Switch
0130F00498
(-.45 / -.85)
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.)
0 - 7,000 #45 1.25mm
Above 7,000 #49 # 56
Bur ner Orifice Size
Natural Propane
Table 2
CONTENTS
ATTENTION INSTALLING PERSONNEL......................... 1
DESCRIPTION .................................................... 1
IMPORTANT INFORMATION..................................... 2
HASFK-2 .......................................................... 2
Orifice and Pressure Switch Assembly Installation....... 2
Adjustments and Checks .................................... 3
Manifold Pressure Check .................................... 4
Inspect Burner Flame ........................................ 4
Check and Adjust Unit T emperature Rise ................. 4
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 derate. Orifice selection is based on non-derated gas [at standard conditions
of 29.92 in Hg and 60°F—approximately 1,000 Btu/ft
natural gas and 2,500 Btu/ft
tent of your gas supply has been artificially changed to account for altitude, contact your gas supplier for orifice sizing (orifice may not require change).
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for propane]. If the Btu con-
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for
IO-833
1/2015
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IMPORTANT INFORMATION
absence, follow the latest edition of the National Fuel Gas
Code (NFPA 54/ANSI Z223.1), and/or CAN/CSA B149.1 Installation Codes.
HASFK-2
The conversion from “standard altitude” natural gas orifices
and pressure switch assembly (as shipped from the factory)
to “high altitude” natural or propane orifices and pressure
switch assembly requires the following tools and supplies:
• 1 - 7/16” box wrench
• 1 - 1/4” nut driver
• 1 - 3/16” allen wrench
• 1 - 1/4” flat blade screwdriver
• 1 - Manometer to read inlet and outlet pressure of the
gas valve (minimum range: 0” - 20” W.C.)
• Gas leak detection solution like soap and water solution. always wipe the solution from the joints when
testing is completed.
Before proceeding, shut OFF gas supply at manual shut-off
and turn off power to the unit.
ORIFICE AND PRESSURE SWITCH ASSEMBLY
INSTALLATION
Contact a local propane gas supplier
about installing a gas detecting warning device.
1. Shut OFF gas supply at manual shutoff and turn OFF
power to the unit.
2. Remove access door.
3. Disconnect wiring from the gas valve.
Burner Bracket
Burner
Manifold
Gas Valve
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
Figure 1
Gas Manifold Removal
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4. Remove the screws securing the gas manifold and valve
to the burner bracket and retain. Separate gas manifold
and valve from burner bracket.
NOTE: If Natural Gas conversion proceed to step 5 and upon
completion of step 5 skip to step 9.
If Propane Gas conversion skip step 5 and jump to step 6
PROPANE GAS BURNER ORIFICE and GAS VALVES SPRING
REPLACEMENT step.
5. NATURAL GAS BURNER ORIFICE REPLACEMENT
a. Remove standard altitude natural gas orifices from
gas manifold using a box end wrench.
b. Visually inspect Natural gas high altitude orifices
(B2589907) for damage and drill size (marked on face
with #49) before installation. Using 7/16" box-end
wrench, remove all existing #45 natural gas orifices
and replace with the appropriate #49 natural gas high
altitude orifices supplied in the kit. Tighten orifices
with a box-end wrench; do not cross-thread or overtighten. Orifice usage depends on an installation’s
gas usage and altitude.
6. PROPANE GAS BURNER ORIFICE AND GAS VALVES SPRING
REPLACEMENT
IMPORTANT: propane gas is heavier than air and
does not vent upward as natural gas fuels.
a. Remove standard altitude natural gas orifices from
gas manifold using a box end wrench.
b. Visually inspect P ropane gas high altitude orifices
(B2589908) for damage and drill size (marked on
face with #56) before installation. Using 7/16" boxend wrench, remove all existing #45 natural gas
orifices and replace with the appropriate #56 propane gas high altitude orifices supplied in the kit.
Tighten orifices with a box-end wrench; do not
cross-thread or overtighten. Orifice usage depends
on an installation’ s gas usage and altitude.
c. Remove both regulator cover screws from gas
valve.
d. Using a ¼” flat blade screwdriver, remove both
regulator adjustment screws (beneath the cover
screw),
e. Remove both Natural gas regulator springs (color-
coded silver/plain) from regulator sleeves and retain with the Natural Gas orifices for future
reconversion.
f. Insert the L.P. regulator springs (provided in the
conversion kit and color-coded white) into the
regulator sleeves.
7. Replace the High regulator adjustment screw and adjust until screw reaches the bottom stop. Then follow
the instructions in the Adjustment and Checks section
to verify manifold pressure falls into the desired range.
See T able 4.
8. Replace the Low regulator adjustment screw and adjust
until screw reaches the bottom stop. Then follow the
instructions in the Adjustment and Checks to verify
manifold pressure falls into the desired range. See
T able 4.
9. PRESSURE SWITCH ASSEMBLY INSTALLATION
a. Locate two-stage pressure switch assembly located
on the induced draft blower .
NOTE: Single pressure switch with two gray wires
does not require a change.
b. Disconnect the pressure switch hose from the pres-
sure switch assembly tee.
c. Disconnect high stage (yellow and orange) and low
stage (brown and orange) wiring from pressure
switches.
d. R emove mounting bracket screw securing standard
altitude pressure switch assembly to induced draft
blower.
e. Install high altitude pressure switch assembly
0130F00498 using screw removed in Step 4.
f. Reconnect wiring to pressure switch assembly.
g. Reconnect pressure switch hose to new assembly .
Gas
Valve
Pressure
Switches
Induced
Draft Blower
Figure 2
(Upflow shown, counterflow similar)
ADJUSTMENTS AND CHECKS
The following adjustments and checks are a required part of
this conversion. Adjustment and checks include:
• Leak checking orifices.
• Checking and adjusting line and manifold gas pressures.
• Verifying proper unit operation (input rate, operational
sequence, burner flame, temperature rise, etc.).
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Propane Gas Manifold Pressure
Low Stage High Stage
5.7 to 6.3" w.c. 9.7 to 10.3" w.c.
Table 4
1. Connect a calibrated water manometer or appropriate
gas pressure gauge at either the gas valve inlet pressure
tap or gas piping drip leg. The gas supply and manifold
pressure on White-Rodgers 36J54 gas valves, used on
single and two stage furnaces, can be checked with a gas
pressure test kit (Part # 0151K00000S) available through
our authorized distributors.
2. Turn ON the power and gas, put the unit into heating
cycle and turn on all other gas consuming appliances.
3. Leak check burner orifice threads using soap solution.
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. The inlet gas pressure for
propane gas must be between 11.0 and 13.0 inches W.C.
If supply pressure differs from required, make necessary
adjustments to pressure regulator(s), gas piping, etc.
5. T urn OFF gas to the unit at the manual shutoff valve and
disconnect manometer . R einstall line pressure tap plug.
T urn OFF any unnecessary appliances started in step 2.
t
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n
a
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m
e
Open to
Atmosphere
M
H
o
s
e
Outlet
Pressure Boss
High Fire Regulator
Adjust
Regulator
Vent
1. T urn OFF gas to the unit at the manual gas shutoff valve.
2. Connect a calibrated water manometer or appropriate
gas pressure gauge at the gas valve outlet pressure tap.
The gas supply and manifold pressure on White-Rodgers
36J54 gas valves, used on single and two stage furnaces,
can be checked with a gas pressure test kit (Part #
0151K00000S) available through our authorized
distributors.
3. T urn ON gas supply and operate unit.
4. Remove the cap screw from the high stage manifold
pressure regulator adjustment location.
5. Using an Allen wrench, adjust high stage manifold regulator
to the required manifold pressure (Table 3 for Natural
Gas or Table 4 for Propane Gas).
6. Reinstall the high stage manifold pressure regulator cap
screw . Confirm high stage manifold pressure.
7. Remove the cap screw from the low stage manifold
pressure regulator adjustment location.
8. Using an Allen wrench, adjust low stage manifold regulator
to the required manifold pressure.
9. Reinstall the low stage manifold regulator cap screw.
Confirm low stage manifold pressure.
10. Turn OFF gas supply to unit. Disconnect manometer and
reinstall manifold pressure tap plug.
Low Fire
Regulator
Inlet
Pressure
Boss
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F
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(
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)
H
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Common
Terminal(C)
Adjust
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Figure 3
White-Rodgers Model 36J54 Connected to Manometer
MANIFOLD PRESSURE CHECK
Only small variations in gas flow should be made by adjusting
the gas valve pressure regulator. See Table 3 for the required
natural gas manifold pressure and see Table 4 for the required propane gas manifold pressure.
Natural Gas Manifold P ressure
Low Stage High Stage
1.6 to 2.2" w.c. 3.2 to 3.8" w.c.
Table 3
INSPECT BURNER FLAME
The burner flames should be stable, soft and blue (dust may
cause orange tips but they must not be yellow). They should
extend directly outward from the burners without curling,
floating, or lifting off.
Figure 4
Burner Flame
CHECK AND ADJUST UNIT TEMPERATURE RISE
Check and adjust unit temperature rise(s) as described in
the installation manual.
Temperature rise must be within the range shown on the
furnace rating plate.
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