International Comfort Products NAHA00101MH Installation Manual

INSTALLATION INSTRUCTIONS

MANUFACTURED (MOBILE) HOME KIT

Condensing Gas Furnace Conversion

NAHA00101MH

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.

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

AVERTISSEMENT

gloves. Have a fire extinguisher available during start−up, adjustment steps, and service calls.

Recognize safety information. This is the safety−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 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.

INTRODUCTION

! WARNING

FIRE, EXPLOSION, ELECTRICAL SHOCK AND 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.

! WARNING

FIRE, EXPLOSION, ELECTRICAL SHOCK HAZARD

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

Gas supply MUST be shut off before disconnecting electrical power and proceeding with conversion.

This instruction covers the installation of kit Part No. NAHA00101MH in the following gas furnaces for manufactured (mobile) home applications.

This kit is only for use in single stage 40,000 through 120,000 Btuh gas input models when installed as a direct vent (2−pipe) furnace.

NOTE: This kit is not approved for the 140,000 Btuh gas input model furnace, any two−stage and variable speed models, any non−direct vent (1−pipe) applications nor any furnace that does not have a sealed combustion system with provisions for outside air.

40,000 to 120,000 BTUH MODEL NUMBERS

BEGINNING WITH:

G9MXE F9MXE N9MXB N9MSB N9MSE

Specifications subject to change without notice.

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Table 1 Kit Contents

Qty. Description

1 Adjustment Tool 1 Drill Bit 7/64” 1 Gas Valve 1 Connector 1/8” NPT 1 Elbow, Street Brass 1/8” NPT 1 Elbow, Street 150# 1/8” NPT 1 Tee, Street Brass 1 Tee Brass 1 Nipple HEX Brass 7 Screw HEX HD 8AB 3/4 1 Pressure Switch 1 Wire Tie 7 Orifice 1.25mm 1 Wire Assembly 1 Wire Assembly 1 Installation Label 322236−101 1 Adhesive Pouch 337985−101 1 Label, Conversion 337993−101 1 Conversion Rating Plate 338299−101 1 Instructions

DESCRIPTION AND USAGE

This kit is designed for use in the furnaces listed in the Introduction. This kit is required for furnaces that use natural gas or propane gas. These instructions describe the modifications required for use in a manufactured (mobile) home. See Table 1 for kit contents.

This conversion uses a White−Rodgers 36J convertible (natural or propane) gas valve. More parts are shipped in the kit than will be needed to complete the conversion. When installation is complete, the extra parts are to remain with the furnace for future use.

This furnace must be installed in accordance with the manufacturer’s instructions and Manufactured Home Construction and Safety Standard, Title 24 CFR, Part 3280 or, when such standard is not applicable, the ANSI A225.1, Standard for Manufactured Home Installation (Manufactured Home Sites, Communities and Set−Ups), or the Mobile Homes Standard CAN/CSA−Z240 MH Series−09.

Ce générateur d’air chaud doit être installé conformément avec les instructions du fabricant et la norme intitulée Manufactured Home Construction and Safety Standard, Title 24 CFR, Part 3280 ou, lorsque cette norme ne s’applique pas, la norme ANSI A225.1, intitulée Standard for Manufactured Home Installation (Manufactured Home Sites, Communities and Set−Ups), ou la norme CAN/CSA−Z240 MH Série 09 de I’ACNOR, intitulée Maisons mobiles.

This furnace must be installed as a direct−vent/2−pipe (combustion air and flue) system. In a direct−vent system, all air for combustion is taken directly from the outside atmosphere, and all flue products (exhaust) are discharged to the outside atmosphere. See furnace and factory accessory concentric vent instructions for proper installation.

NOTE: The factory accessory concentric vent when used for sidewall termination MUST NOT project more than 3−in. (76 mm) beyond the surface of the wall. See the appropriate section for installation modification.

SECTION I: Initial Kit Installation SECTION II: Conversion from Natural Gas to Propane SECTION III: Conversion from Propane to Natural Gas

SECTION I: INITIAL KIT INSTALLATION

Procedure 1 — General

A downflow furnace application is where furnace blower is located above combustion and controls section of furnace, and conditioned air is discharged downwards.

Attach adhesive pouch containing literature packet and gas conversion parts to outside of main furnace door or accessible side of furnace for use at a later date. (See Figure 1)

! WARNING

PERSONAL INJURY AND UNIT DAMAGE HAZARD

Failure to follow this warning could result in personal injury or unit damage.

When installing the air conditioning coil casing or when servicing air conditioning, caution must be taken to ensure furnace will not fall forward.

! CAUTION

UNIT DAMAGE HAZARD

Failure to follow this caution may result in damage to the unit.

To prevent damage during transportation of the home, coil casing must be secured to the floor, furnace and coil casing must be fastened together, and furnace must be secured to wall of the structure. When a coil casing is not used, an accessory floor base is required. (See furnace rating plate or clearance label for special accessory floor base part number.) Secure floor base to structure and attach furnace to floor base.

RECOMMENDED METHODS OF SECURING FOR TYPICAL INSTALLATION (See Figure 1)

All mounting hardware is field−supplied.

1. Secure coil casing to floor.

a. Secure coil casing to floor of structure using 5/16−in.

(8 mm) lag screws (one each side) through lower inside flanges of coil casing.

b. Alternate method: Attach right angle mounting

brackets or pipe strap (bent 90 degrees) to coil casing using No.10 self tapping screws. Attach other end of brackets/strap to floor of structure using 5/16−in. (8 mm) lag screws. If coil is present in casing, be careful not to damage condensate pan with tip of screw or remove coil from casing.

2. Fasten furnace to coil casing. Be careful not to damage it

with tip of screw. a. Secure furnace to coil casing using two (2) No.10 self

tapping screws (one on each side of burner enclosure) through cell panel flange, lower furnace casing plate, and coil casing top flange.

b. Alternate method: Attach pipe strap to both furnace

casing and coil casing (one each side).

3. Secure furnace to structure.

a. Attach pipe strap to top of furnace casing using

No.10 self− tapping screws. Angle strap down and away from back of furnace, remove all slack, and fasten to wall stud of structure using 5/16−in. (8 mm) lag screws. Typical both sides of furnace.

b. Alternate method: Secure furnace to wall stud using

1/8−in. (7 mm) thick right−angle brackets. Attach brackets to furnace using No.10 self tapping screws, and to wall stud using 5/16−in. (8 mm) lag screws.

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Specifications subject to change without notice.

Figure 1 Securing Furnace to Structure

WALL STUDS

RETURN AIR PLENUM

(WHEN USED)

SECURE FURNACE TO STRUCTURE

AT TAC H

ADHESIVE

POUCH TO

DOOR

OR SIDE

FURNACE

COIL

CASING

PIPE STRAP-REMOVE SLACK

(TYPICAL BOTH SIDES)

1/8-IN. (7 MM) THICK ANGLE

MOUNTING

BRACKET (TYPICAL BOTH SIDES)

FASTEN FURNACE TO CASING

SCREWS THROUGH

CASING FLANGES

PIPE STRAP FASTENED TO

FURNACE AND COIL CASING SIDES

(TYPICAL BOTH SIDES)

1-IN. (25 MM) MAXIMUM

SECURE COIL CASING TO FLOOR

LAG SCREWS THROUGH COIL CASING

FLANGE (TYPICAL BOTH SIDE)

ANGLE BRACKET OR PIPE STRAP

NOTE: USE 5/16-IN. (8 MM) LAG SCREWS WHEN SECURING TO STRUCTURE WALLS AND FLOOR. USE NO. 10 SELF-TAPPING SCREWS WHEN FASTENING TO SHEET METAL.

A11492

WHEN COIL CASING IS NOT INSTALLED (NOT SHOWN)

1. Accessory floor base MUST be used. Review floor base

! PRUDENCE

Installation Instructions before installation.

2. Secure accessory floor base to structure using 5/16−in. (8 mm) lag screws.

3. Fasten furnace to accessory floor base using No.10 self tapping screws through tabs on both sides of base (two each side).

D’EQUIPEMENT D’OPERATION

Toute erreur de câblage peut être une source de danger et de panne.

Lors des opérations d’entretien des commandes, étiqueter tous les fils avant de les déconnecter.

Procedure 2 — Replace Gas Valve

! WARNING

! CAUTION

UNIT OPERATION HAZARD

Failure to follow this caution may result in unit damage or improper operation.

Label all wires prior to disconnection when servicing controls.

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Specifications subject to change without notice.

FIRE, EXPLOSION, ELECTRICAL SHOCK HAZARD

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

Gas supply MUST be shut off before disconnecting electrical power and proceeding with conversion.

! 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.

Figure 4 Convertible Gas Valve

LP/NAT CONVERTIBLE CAP

NAT

ON/OFF SWITCH

REGULATOR PLUNGER

GAS PRESSURE REGULATOR

Figure 2

Furnace Support for Servicing Air Conditioner

FURNACE

FIELD-SUPPLIED

SUPPORTS

(1 X 4 (25 X 102 mm)

OR 2 X 4 (51 X 102 mm)

3 PLACES)

Figure 3 Manifold Assembly

Orifice

Connect Green/Yellow ground wire here

Gas valve is parallel to manifold

within + or - 3˚

Manifold

Gas Valve

Gas valve must be installed on manifold with minimum engagement of 6 threads. Cross threading is not acceptable.

Indicated surfaces

˚+ or -2˚

to be 90

A99007

A11407

INLET PRESSURE TAP

MANIFOLD PRESSURE TAP

A11510

1. Set room thermostat to lowest setting or OFF.

2. Disconnect power at external disconnect, fuse or circuit breaker.

3. Turn off gas at external shut−off or gas meter.

4. Remove outer doors and set aside.

5. Turn electric switch on gas valve to OFF.

6. Disconnect the gas pipe from gas valve and remove pipe from the furnace casing.

7. Disconnect the connector harness from gas valve Disconnect wires from Hot Surface Igniter (HSI) and Flame Sensor. (See Figure 9)

8. Support the manifold and remove the four (4) screws that secure the manifold assembly to the burner box and set aside.

9. Note the location of the green/yellow wire ground wire for re−assembly later. (See Figure 3)

10. Remove production gas valve from manifold assembly and discard valve.

NOTE: Production gas valve has a slotted cap on regulator adjustment cap. The convertible valve has cap marked NAT and LP.

11. Install new convertible gas valve to manifold. (See

Figure 4)

NOTE: Use a back−up wrench on the gas valve to prevent the

valve from rotating on the manifold or damaging the mounting to the burner box.

NOTE: Use propane−gas−resistant pipe dope to prevent gas leaks. DO NOT use Teflon tape.

INSTALL MANIFOLD−Natural Gas Only

NOTE: Install manifold if conversion is for use with natural gas.

For propane applications, manifold will be installed after Low Gas Pressure Switch is installed.

1. Refer to Figure 3 and Figure 9.

2. Align the orifices in the manifold assembly with the support rings on the end of the burner.

3. Insert the orifices in the support rings of the burners. Manifold mounting tabs should fit flush against the burner box.

NOTE: If manifold does not fit flush against the burner box, the burners are not fully seated forward. Remove the manifold and check burner positioning in the burner box assembly.

4. Attach the green/yellow wire and ground terminal to one of the manifold mounting screws. (See Figure 3)

5. Install the remaining manifold mounting screws.

6. Connect the wires to the flame sensor and hot surface igniter.

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Specifications subject to change without notice.

7. Connect the connector harness to gas valve. NOTE: Use only propane−resistant pipe dope. Do not use Teflon tape.

8. Insert the gas pipe through the grommet in the casing.

Apply a thin layer of pipe dope to the threads of the pipe

and thread the pipe into the gas valve. NOTE: Use a back−up wrench on the gas valve to prevent the valve from rotating on the manifold or damaging the mounting

to the burner box.

9. With a back−up wrench on the inlet boss of the gas valve, finish tightening the gas pipe to the gas valve.

10. Check for leaks after the gas pipe is installed.

NOTE: If you are converting furnace for use with propane, attach kit labels and extra parts bag as described in Procedure

3 then proceed to Section II.

Figure 5 Conversion Responsibility Label

Procedure 3 — Label and Extra Parts Bag Attachment

NOTE: See Figure 6, Figure 7 and Figure 8 for label location.

1. Attach Conversion Responsibility Label (337993−101) inside of main furnace door. (See Figure 7) Date, name, and address of organization making this conversion are required. (See Figure 5)

2. Attach Conversion Rating Plate Label (338299−101) inside of lower left−hand side of controls compartment (downflow) as shown in Figure 6.

3. Attach Manufactured (Mobile) Home Installation Label (322236−101) inside of main furnace door. (See Figure 7)

4. Attach adhesive pouch (337985−101) containing gas orifices and Installation Instructions to front of main furnace door or accessible furnace side. (See Figure 1 or Figure 8)

5. Proceed to Section II or III for gas type modification and Input rate adjustment.

Figure 6 Conversion Rating Plate Label Location

FURNACE CONVERSION

RATING PLATE

REPRESENTATIVE DRAWING ONLY, SOME MODELS MAY VARY.

Figure 7 Installation & Responsibility Label Locations

MANUFACTURED (MOBILE)

INSIDE OF DOORS

REPRESENTATIVE DRAWING ONLY, SOME MODELS MAY VARY.

HOME INSTALLATION LABEL

RESPONSIBILITY LABEL

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Specifications subject to change without notice.

Figure 8 Label Locations

IMPORT

ANT

THIS B

WITH

STRUC

TION

NCLOS

ED M

UST

BE ATTACH

ED T

FURN

ACE

ADHESIVE POUCH

REPRESENTATIVE DRAWING ONLY, SOME MODELS MAY VARY.

SECTION II: CONVERSION FROM NATURAL GAS TO PROPANE

BURNER REMOVAL

1. Slide one−piece burner assembly out of slots on sides of burner box.

2. Remove the flame sensor from the burner assembly.

3. Remove the natural gas orifices from the manifold and discard.

Figure 9 Burner Assembly

IGNITER

FLAME ROLL-OUT SWITCH

Figure 10 Burner Orifice

BURNER ORIFICE

A96249

Refer to conversion kit rating plate 338298−101 to determine main burner orifice size. (See Figure 12)

Furnace gas input rate on furnace rating plate is for installations at altitudes up to 2000 ft. (610 M).

In the U.S.A., the input rating for altitudes above 2000 ft. (610 M) must be reduced by 2 percent for each 1000 ft. (305 M) above sea level.

In Canada, the input rating must be derated by 5 percent for altitudes of 2000 ft. to 4500 ft. (610 M to 1372 M) above sea level.

The Conversion Kit Rating Plate accounts for high altitude derate.

INSTALL ORIFICES

1. Install main burner orifices. Do not use Teflon 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: There is a set of mixer screws. Use the parts in the bag

marked “REQUIRED FOR THE CONVERSION OF CONDENSING GAS FURNACES TO PROPANE GAS”

1. See Figure 11 to verify you have the correct set of mixer screws.

2. Locate the dimple on each burner venturi tube.

3. If you cannot locate the dimple, refer to Figure 13 for location of the mixer screw.

4. Drill a 7/64−in (2.8 mm) hole (supplied in kit) in each dimple.

5. Install a mixer screw in each drilled hole drilling as straight as possible (i.e. in the center of the gas flow stream as well as perpendicular to the gas flow stream).

6. The screw head should be flush with the top of the burner venturi.

Figure 11 Gas Conversion Kit

FLAME SENSOR (BELOW BURNER)

A11226

ORIFICE SELECTION/DERATE

! WARNING

FIRE AND FURNACE DAMAGE HAZARD

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

DO NOT redrill orifices. Improper drilling (burrs, out−of−round holes, etc.) can cause excessive burner noise and misdirection of burner flames. This can result in flame impingement of burners and heat exchangers causing failures.

A11294

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Specifications subject to change without notice.

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