ICP NAHA00701NG Installation Instructions Manual

INSTALLATION INSTRUCTIONS

For Propane to Natural Gas Conversion Kit Model No:

NAHA00701NG or Part No. (1178474)

This kit is designed to convert *9UHX and *9MPX Natural Gas furnace to Propane Gas furnace.

SAFETY CONSIDERATIONS

Improper installation, adjustment, alteration, service,
maintenance, or use can cause explosion, fire, electrical shock,

or other conditions which may cause death, personal injury, or
property damage. Consult a qualified installer, service agency, or

your distributor or branch for information or assistance. The
qualified installer or agency must use factory-authorized kits or
accessories when modifying this product. Refer to the individual

instructions packaged with the kits or accessories when installing.
Follow all safety codes. Wear safety glasses, protective clothing,

and work gloves. Use quenching cloth for brazing operations.
Have fire extinguisher available. Read these instructions
thoroughly and follow all warnings or cautions included in

literature and attached to the unit. Consult local building codes,
the current editions of the National Fuel Gas Code (NFCG) NFPA

54/ANSI Z223.1, National Electrical Code (NEC) NFPA 70.
In Canada refer to the current editions of the National standards

of Canada CAN/CSA-B149.1 and .2 Natural Gas and Propane
Installation Codes, and Canadian Electrical Code CSA C22.1.

Recognize safety information. This is the safety-alert symbol /_
When you see this symbol on the unit and in instructions or

manuals, be alert to the potential for personal injury. Understand
these signal words; DANGER, WARNING, and CAUTION. These

words are used with the safety-alert symbol. DANGER identifies
the most serious hazards which will result in severe personal

injury or death. WARNING signifies hazards which 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

which will result in enhanced installation, reliability, or operation.

General Information

This kit is for conversion of furnaces equipped with Single Stage
Honeywell VR8205S Series gas valves from propane gas to natural
gas. Before the furnace can be operated with natural gas, the low

inlet pressure switch must be removed. A gas valve conversion kit
must be installed and main burner orifices must be replaced with ori-
fices inthis kit or with properly sized orifices for high altitude (ordered
separately).

* Denotes Brand (T, H or C)

FIRE, EXPLOSION, ELECTRIC SHOCK, AND CAR-
BON MONOXIDE HAZARD.

This conversion kit shall be installed by a qualified
service technician in accordance with the Manufac-

turer's instructions and all applicable codes and re-

quirements of the authority having jurisdiction. If

the information in these instructions is not followed

exactly, a fire, an 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 kit. The installation is not proper and complete

until the operation of the converted appliance is
checked as specified in the manufacturer's instruc-

tions supplied with the kit.

Cette trousse de conversion dolt 6tre install6e par

un service d'entretien qualifi6, selon les instruc-

tions du fabricant et selon toutes les exigences et
tous les codes pertinents de rautorite competente.

Assurezvous de bien suivre les instructions dans

cette notice pour r6duire au minimum le risque d'in-
cendie, d'explosion ou la production de monoxyde

de carbone pouvant causer des dommages mate-
riels, des blessures ou la mort. Le service d'entreien

qualifi6 est responsable de rinstallation de cette

trousse. L'installation n'est pas ad6quate ni com-

pl6te tant que le bon fonctionnement de rappareil
convertin'a pas 6te verifi6 selon les instructions du

fabricant fournies avec la trousse.

Parts List

Description
Burner Orifice #44

Honeywell Conv. Kit (396222)
Label, Field Conversion
Label, Nat Conversion
Label, Conversion
Label, Derate

Instructions 441 06 1083 00
Orifices for High Altitude Conversion

(Not included in kit)
(Referto Table 1- for required orifice)

Part#

1011352

330732-401

1009678
336083-101
336082-101
334836-101

Qty.

6
1
1
1
1
1

1

Burner Orifice #41
Burner Orifice #42
Burner Orifice #43
Burner Orifice #45
Burner Orifice #46

Specificationssubjecttochangewithoutnotice. 441 06 1083 00 June 2009

1096942 as required

1011351 as required
1011377 as required
1011353 as required

1011744 as required

The orifices provided in this kit are stamped to indicate the size (twist

drill number). 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, espe-
cially 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.

Installation

ELECTRIC SHOCK, FIRE AND EXPLOSION
HAZARD.

Failure to follow this warning could result in
personal injury, death, equipment damage, and/or
property damage.

Turn OFF gas supply at manual gas valve before
turning OFF electric power supply and starting

conversion.
Turn OFF electric power supply at disconnect

switch or service panel before starting
conversion. Tag and lockout shutoff(s) with appro-

priate device warning labels. There may be more

than one disconnect.

Disassembly

Refer to Figure 1 and the following steps.

1. After disconnecting power and gas supply to the furnace, re-
move the access door, exposing gas valve and burner
compartment.

2. Disconnect the yellow wire harness from the two terminals on
the Propane switch, the air pressure switch, and furnace har-

ness.

3. Reconnect yellow furnace harness wire to air pressure switch.
See furnace wiring label.

4. Disconnect gas line from fitting assembly so manifold assembly
can be removed.

5. Disconnect wiring at gas valve. Be sure to note the proper loca-
tion of any and all electrical wiring disconnected.

6. Remove the four (4) screws holding the manifold and gas valve
to the manifold supports. Do not discard any screws.

7. Carefully remove the manifold assembly and remove fitting as-
sembly from the gas valve.

8. Unscrew the Propane pressure switch from the bushing.

Figure 1 Disassembly

Changing Main Burner Orifices

1. Remove the Propane (silver) orifices burner orifices from the
manifold assembly and replace them with the Natural gas (typi-
cally black) furnished in the conversion kit or called out in

Table 1. (See Figure 2).

2. Tighten the orifices so they are seated and gas tight about
11/8" from the face of the orifice to the back of the manifold pipe
(Figure 3). Make sure orifice is installed straight so that it forms

a right angle (90 °) to the manifold.

Figure 2

Remove Orifices

25-21-00

Figure 3 Changing Orifices

I _ Measure fromface oforifice to
_ 4 the back side of the manifold.

1.11"(28.2mm) _',',',',',',',','_

__>1.21" (30.8mm) <_

High Altitude Installation

Gas input rate on the furnace rating plate is for installation at up to
2000'. The #44 burner orifices supplied in this kit are sized for Natural
Gas at full rate ONLY, for use between 0-2000' (0-609.6m) elevation.
Do not use them above 2000' (609.6m) except when noted by

Table 1. Orifices for conversion at high altitude must be ordered from

Service Parts.

In the USA, derating of these furnaces at 2% (Natural Gas)
and 4% (Propane Gas) has been tested and design-certified

by CSA.

1- In Canada, the input rating must be derated 5% (Natural Gas)

and 10% (Propane Gas) for altitudes of 2,000 to 4,500 (609.6

to 1371.6m) above sea level. Use the 2001 to 3000 (609.9 to

914.4m) column in Table 1.

..... ....... ....

44106 108300 Specifications subject to change without notice. 2

Figure 4 Ignitor Location in(mm)

21/16(52.39)

...... 1/4(6.4 )

A .

Y _',ii Jill

.....-_.i_.......

NOTE: Flame sensor has a different orientation in all 050
and alternate 040 input models.