Installation Instructions For Natural Gas Conversion
(Kit Part No. 1173865)
This kit is designed for conversion to Natural Gas.
Table 1
0 to 2000 ft
PGAA, PGMD (All Sizes)
PGAD, PGME (All Sizes)
PGX3, PDX3 (All Sizes)
PGC***K040F, GPCM**K040
PGC***K060F, GPCM**K060
PGC***K080F, GPCM**K080
PGC***K100F, GPCM**K100
PGC***K120F, GPCM**K120
PGC***K140F, GPCM**K140
PGF***K040F, GPFM**K040
PGF***K060F, GPFM**K060
PGF***K080F, GPFM**K080
PGF***K100F, GPFM**K100
PGF***K120F, GPFM**K120
PGF***K140F, GPFM**K140
PGS***K040F, GPSM**K040
PGS***K060F, GPSM**K060
PGS***K080F, GPSM**K080
PGS***K100F, GPSM**K100
PGS***K120F, GPSM**K120
PGS***K140F, GPSM**K140
PGF3**040
PGF3**060
PGF3**080
PGF3**100
PGF3**120
PGF3**140
Note: "**" or "***" may be any combination of numbers and/or letters in the model number.
Note: The orifice sizes in the chart above derate the inpu t rate at 4% per 1000 feet above sea level for altitudes exceeding 2000 feet above sea level.
Natural gas data is based on .60 sp ecific gravity, a heating value of 1030 Btu/cubic foot, and 3.5 "W.C. manifold pressure.
For fuels with different specific gravity and/or different heating values, consult the National Fuel Gas Code ANSI Z223.1 - 2002/NFPA 54-2002 or
National Standard of Canada, Natural Gas and Propane Installation Code CSA B149.1-00.
Note: If converting from LP gas to Nat ural gas at altitudes exceeding 2000 feet above sea level, conversion kit (Part #330732-401) is required for proper conversion. For all models, except PGX3, PDX3, and PGF3, a .018 pilot
orifice (Part # 5032110) is also required.
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2001 to 4000 ft 4001 to 5000 ft 5001 to 6000 ft 6001 to 7000 ft 7001 to 8000 ft 8001 to 9000 ft 9001 to 10000 ft
Orifice Drill #
(Field-Supplied)
Natural Gas Orifice Kits and Sizes
Elevation Above Sea Level
Orifice Drill #
(Field-Supplied)
Orifice Drill #
(Field-Supplied)
Orifice Drill #
(Field-Supplied)
Orifice Drill #
(Field-Supplied)
Orifice Drill #
(Field-Supplied)
Orifice Drill #
(Field-Supplied)Model Numbe r Orifice Drill # Kit Number
Parts List, Kit # 1173865
Description Part # Qty
Burner Orifice #41 1096942 7
Burner Orifice #42 1011351 7
Pilot Orifice (0.018) 503211 1
Honeywell Conv. Kit #396222 1172952 1
Label, Natural Gas Conversion 1173866 1
Label, Field Conversion 1009678 1
Instructions 462 06 1211 00 1
SAFETY REQUIREMENTS
Recognize safety information. This is the safety--alert symbol .
When you see this symbol in instruction manuals be alert to the
potential for personal injury.
Understand the signal words DANGER,WARNING, or CAUTION.
These words are used with the safety--alert symbol. DANGER
identifies the most serious hazards, those that 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 that 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.
!
-- 1 --
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 service personnel can perform basic maintenance
functions such as cleaning and replacing air filters. All other
operations must be performed by trained service personnel. When
working on heating equipment, observe precautions in the
literature, on tags, and on labels attached to or shipped with the
appliance and other safety precautions that may apply.
Follow all safety codes. In the United States, follow all safety codes
including the National Fuel Gas Code (NFGC) ANSI
Z223.1--2006/NFPA 54--2006. In Canada, refer to the of the
National Standard of Canada Natural Gas and Propane
Installation Code (NSCNGPIC) CSA B149.1--05. Wear safety
glasses and work gloves. Have fire extinguisher available during
start--up and adjustment procedures and service calls.
These instructions cover minimum requirements and conform to
existing national standards and safety codes. In some instances,
these instructions exceed certain local codes and ordinances,
especially those that may not have kept up with changing
residential construction practices. We require these instructions
as a minimum for a safe installation.
462 06 1211 00
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Important Information
This kit includes a Honeywell conversion kit for converting
Honeywell VR8200, VR8205S, SV9500, SV9501 or VR8204M
gas valves certified for use with Propane Gas (and so marked) to
units functionally the same as the certified furnace for use with
Natural Gas. If converting from propane gas to natural gas, the
gas valve conversion kit, main burner orifices, and pilot orifice, all
found in this kit, must be installed.
For converting the furnace from standard altitude on natural gas to
high altitude (2001 feet above sea level or greater) on natural gas,
the Honeywell conversion kit and pilot orifice changes are not
needed. Only the main burner orifices require changing. Refer to
Tab l e 1 for proper orifice size for specific model number, input
capacity, and installation altitude.
The orifices provided in this kit are stamped to indicate the size
(twist drill number) and are sized for natural gas ONLY. Do NOT
use them with butane or a mixture of butane and propane. The
parts list specifies the size orifices supplied in the kit. Compare the
size marking on the orifices with the sizes as listed in the parts list.
Make sure you have the correct main burner orifices.
Extreme care is used to assure that this kit contains the proper
orifices. Oversized orifices could result in hazardous
conditions, especially if the venting is inadequate. For that
reason, we recommend that the installer check the size of the
orifice with a new twist drill of the correct size. This procedure
assures that the orifices provided are the correct size.
D Fill out and attach the Field Conversion Label to the front ex-
terior of the furnace.
!
FIRE, EXPLOSION, CARBON MONOXIDE
POISONING HAZARD.
Failure to follow these instructions exactly could
result in personal injury, death and/or property
damage.
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, an
explosion or production of carbon monoxide may
result causing property damage, personal injury
or loss of life. The qualified service agency is
responsible for the proper installation of 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.
Gas Pressure
!
ELECTRIC SHOCK HAZARD/FIRE AND/OR
EXPLOSION HAZARD.
Failure to follow this warning could result in
equipment damage, personal injury, death
and/or property damage.
The gas supply shall be shut OFF prior to
disconnecting the electrical power, before
proceeding with the conversion.
Turn OFF electric power supply at disconnect
switch or service panel before starting
installation.
D Shut off gas supply to furnace at manual shut--off valve be-
fore starting installation.
!
EXPLOSION HAZARD
Failure to follow this warning could result in
personal injury, death and/or property damage.
If unit is still running, allow 2.5 minutes after gas
shut off before turning off power, Shut Off electric
power at unit disconnect and service panel.
D Disconnect electric power supply to the furnace before
starting installation.
D Check for gas leaks after installation of kit and before at-
tempting to start furnace.
D Locate the Natural Gas Conversion Label next to the fur-
nace rating plate.
D Refer to the furnace rating plate for the approved gas input
rating.
D Gas input to burners MUST NOT exceed the rated input
shownonratingplate.
D Do NOT allow minimum gas supply pressure to vary down-
ward. Doing so will decrease input to furnace. Refer to
Tab l e 2 for gas supply and manifold pressures.
Table 2
Gas Supply Pressure Manifold
Type Recommended Max. Min. Pressure
Natural 7″ 13″ 4.5″ 3.5″
Gas Pressures
Installation
!
ELECTRIC SHOCK HAZARD/FIRE AND/OR
EXPLOSION HAZARD.
Failure to follow this warning could result in
property damage, equipment damage, personal
injury and/or death.
Turn OFF gas supply at manual gas valve
before turning OFF electric power supply and
starting installation.
Turn OFF electric power supply at disconnect
switch or service panel before starting
installation.
-- 2 --
462 06 1211 00
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Disassembly
Refer to Figure 1 and the following steps.
Figure 2
Installing NOx Baffles
Figure 1
1. After shutting off gas supply and electric power to the unit
remove the access door, exposing gas valve and burner
compartment.
2. Disconnect gas line from gas valve so manifold assembly
can be removed.
3. Disconnect wiring at gas valve. Be sure to note the proper
location of any and all electrical wiring disconnected.
4. If converting from Propane Gas to Natural Gas, remove the
pilot supply line from the gas valve.
5. Remove the four (4) screws holding the manifold and gas
valve to the manifold supports. Do Not discard any screws.
6. Carefully remove the manifold assembly.
7. If converting from Propane Gas to Natural Gas in the state of
California, NOx baffles must be installed to comply with
California law. NOx baffles can be ordered from Fast Parts.
Remove the two (2) screws holding the burner assembly in
place. Install the correct NOx baffle for the unit, if required,
and replace the Burner Assembly using the original two
screws, Figure 2.
Disassembly
or
Changing Main Burner Orifices
1. Remove the gas burner orifices from the manifold assembly
using a box end wrench or socket wrench, figure 3, and replace them with the proper orifice size for the specific furnace model, input size, and altutude from table 1.
Figure 3
2. Tighten the orifices so they are 13/16″ from the face of the
orifice to the backside of the manifold (See Figure 4).Make
sure orifice is installed straight so that it forms a right angle
(90°) to the manifold.
Changing Orifices
-- 3 --
462 06 1211 00
3/17/06
Figure 4
Manifold/Orifice Measurement
Measure 13/16″ from face of orifice
to back edge of manifold pipe.
Changing Pilot Burner Orifice
(Required for Converting from Propane Gas
to Natural Gas) (All models except PGF3,
PGX3, and PDX3).
1. Disconnect the pilot supply line from the pilot burner.
2. Remove pilot orifice from pilot burner. Replace with natural
gas orifice stamped which is provided in kits (Figure 5)
3.. Reconnect the pilot tubing securely to the pilot burner.
4. Verify proper relationship of pilot burner assembly per fig-
ure 6, prior to completing the conversion.
Figure 5
Changing Pilot Orifice
Figure 6 Burner Pilot Assembly
Gas Valve Conversion (Required for Converting
from Propane Gas to Natural Gas)
Conversion of Honeywell VR8200, SV9500, SV9501 and
VR8204M Gas Valves using Natural Gas Conversion Kit #
396222.
1. Remove the regulator cap screw and pressure regulator ad-
justing screw. (See Figure 10)
2. Remove the existing regulator spring from the regulator
housing.
3. Insert the replacement spring (stainless steel) contained in
this kit into regulator housing.
Pilot
Orifice
Figure 7
Inlet Pressure
Tap (Hidden)
INLET
Pilot Adjustment
Outlet Pressure Tap
Connect manometer here to
check outlet pressure. Must be
adjusted per Table 1 .
Typical Gas Valve Honeywell
SV9500
OFF
WARNING
Explosion Hazard.
Serious injory or death
can result.
Read instructions before
operating valve.
Never
operate valve
use tools to
disassemble valve. call a
qualified service technician
.
if the appliance does not
Do not
function properly.
ON
IGNITER
Honeywell
CONTROL
25-50-06
Pilot
Outlet
OUTLET
Wiring
Terminals
-- 4 --
462 06 1211 00
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Figure 8
Inlet Pressure
Tap (Hidden)
Pilot
Adjustment
Outlet Pressure Tap
Connect manometer here to
check outlet pressure. Must be
adjusted per Table 1 .
Figure 9
Regulator Adjustment
Under Cap
INLET
Inlet
Pressure
1
/8NPT
Tap
Figure 10
PRESSURE
REGULATOR
HOUSING
INLET
Typical Gas Valve Honeywell
SV9501
Wiring Terminals
Typical Gas Valve Honeywell
VR8205S
HONEYWELL
V
T
ON
OFF
Typical Honeywell
Regulator Assembly
LP
Gas
Cap Screw Black Silver
Pressure White White
Regulator
Adjusting
Screw
Spring Red Steel
Pilot
Outlet
OUTLET
25--22--25
Outlet
Pressure
Tap
1
OUTLET
25-- 24--98a
Natural
Gas
Stainless
/8NPT
4. Install the pressure regulator adjusting screw. This will set
the manifold pressure close to required setting for normal
operation.
5. Replace the regulator cap screw.
6. Attach gas valve conversion label (found in Honeywell conversion kit) to gas valve.
Reassembly
Reassemble all parts in reverse order as removed. Attach Natural
Gas Conversion Label next to the unit rating plate. Fill out and
attach the Field conversion Label to the front exterior of the
furnace.
D Manifold Assembly -- Be sure to engage the main burner
orifices in the proper openings in the burners.
D Testing for leaks -- After reassembly, turn the gas on and
check all joints for gas leaks using a soapy solution. All
leaks must be repaired immediately.
Start--up and Check--out
1. Remove the plug from the Inlet Pressure Tap on gas valve
and install a manometer. (See Figures 7, 8, 9, & 10)
2. Open manual gas line valve to unit. Check for gas leaks and
correct as necessary. Check supply pressure. Refer to
Tab l e 2 for proper supply pressure values. If not within
these limitations DO NOT OPERATE UNIT, contact gas
supplier.
3. Close manual gas line valve to unit, remove manometer and
replace inlet pressure tap plug.
Gas Valve Adjustment
4. With the gas valve knob in the OFF position, remove the
pressure tap plug from the outlet end of the valve, and connect a “U” tube manometer to the pressure port. (See Fig-
ure7,8,9&10).
5. Turn the gas valve knob to the ON position and restore electrical power to unit. Cycle the main burner on and off several
times to stabilize the pressure regulator diaphragm. This
MUST be done before an accurate pressure reading can be
obtained.
6. With the main burner on, read the pressure gauge. Manifold
pressure should be adjusted to values from Table 2. Turn
pressure regulator adjusting screw clockwise to increase or
counterclockwise to decrease manifold pressure. Burner
Input must not exceed nameplate rating. Refer to Section
“Checking Input Rate”.
7. Turn gas valve to OFF. Remove the pressure gauge and replace the pressure tap plug and pressure regulator cap
screw.
8. With gas valve on, observe furnace through two or more
complete cycles to be sure all controls are operating.
-- 5 --
462 06 1211 00
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!
1
For PGF3, PGX3, and PDX3 models, heating model size is indicated by the
the 5
th
6
th
d 7th ch
the model
For PGF, PGC, PGS models, heating model size is indicated by the
the 8
th
9
th
d 10
th
ch
the model
For GPFM, GPCM, and GPSM models, heating model size is indicated by the
the 8
th
9
th
d 10
th
ch
the model
For PGAA, PGAD, PGCA, and PGCD models, heating model size is indicated by the letter in the 7
th
ch
the model
For PGMD and PGME models, heating model size is indicated by the letter in the 7
th
ch
the model
FIRE AND/OR EXPLOSION HAZARD
Failure to follow this warning could result in personal
injury, death, and/or property damage.
Do NOT attempt to light the burner with a match or
flame of any kind.
HEATING INPUT RATE CHECK
The gas input to the unit is determined by measuring
the gas flow at the meter. Measuring gas flow at the
meter is recommended for natural gas units. To
measure the heating input, perform the following
steps:
1. Turn off all other gas appliances that use the same
meter.
2. Turn off gas supply to unit and attach manifold
pressure gauge as instructed in the ”Gas Valve
Adjustment” section.
3. With gas ON to the unit and the unit operating, record
the number of seconds for the gas meter dial to make
one revolution.
4. Divide number of seconds in Step 3 into 3600
(number of seconds in 1 hour).
5. Multiply result of Step 4 by the number of cubic feet
shown for one revolution of the meter dial to obtain the
cubic feet of gas flow per hour.
6. Multiply result of Step 5 by Btu heating value of gas to
obtain total measured input in Btu/hr. Compare this
input rate with the Required Input Rate for the
installation altitude, as shown in Table 3. Consult with
local gas supplier if the heating value of gas is not
known.
Example: Assume that the size of the meter d ial is 1 cu. ft.,
one revolution takes 44 seconds, and the heating value of
the gas is 1020 Btu/ft3. Proceed as follows:
1. 38 sec. To complete 1 revolution
2. 3600/38 = 94.7
3. 94.7 x 1 = 94.7
4. 94.7 x 1020 = 96,632 Btu/hr
For this example, the nameplate input is 100,000 Btu/hr, so
only a minor change in manifold pressure is required. In no
case should the final manifold pressure vary more than
+-- .3 ”water column from the values in Table 2. Never
exceed the required input rate (Table 3 ).
Table 3
Required Input Rate for All Models
Required Input Rate of Furnace Converted to Natural Gas (Btu/hr)
Heating Model
1
Size
"040" or "B" 40,000 35200 33600 32000 30400 28800 27200 25600 24000
"060" or "C" 60,000 52800 50400 48000 45600 43200 40800 38400 36000
"080" or "D" 80,000 70400 67200 64000 60800 57600 54400 51200 48000
"100" or "E" 100,000 88000 84000 80000 76000 72000 68000 64000 60000
"120" or "F" 120,000 105600 100800 96000 91200 86400 81600 76800 72000
"140" or "G" 140,000 123200 117600 112000 106400 100800 95200 89600 84000
Note:
0-2000 2001-3000 3001-4000 4001-5000 5001-6000 6001-7000 7001-8000 8001-9000 9001-10000
Elevation Above Se a Level (feet)
numbers in
numbers in
numbers in
,
, an
aracter in
,
,
, an
, an
aracters in
aracters in
aracter in
number.
aracters in
number.
number.
number.
number.
-- 6 --
462 06 1211 00
3/17/06
Pilot Burner Flame Check (All models
except PGF3, PGX3, and PDX3)
Adjust flames so they surround3/8″ (9 mm) to1/2″ (13 mm) of the
sensor tip (See Figure 11).
1. Remove the cap from the pilot adjusting screw (See Fig-
ures7&8).
2. Turn pilot adjusting screw counterclockwise to increase,
clockwise to decrease.
3. Replace the cap on the pilot adjusting screw.
Figure 11
Pilot Burner (HSP)
Main Burner Flame Check
Check for the following:
D Stable and blue flames (See Figure 12). Dust may cause
orange tips or wisps of yellow, but flames MUST NOT have
solid, yellow tips.
D Flames extending directly from burner into heat exchanger.
D Flames DO NOT touch sides of heat exchanger
Figure 12
Main Burner
BLUE FLAME
Proper Flame
Adjustment
Sensor Tip
Hot Surface
Igniter
25--00--07a
1 0 -- 11 -- 6 5
-- 7 --
462 06 1211 00
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