International Comfort Products NAHB01001LP Installation Manual

INSTALLATION INSTRUCTIONS

NATURAL GAS to PROPANE GAS CONVERSION KIT

Condensing and Non−Condensing Gas Furnaces

(F/G)9MAC, (F/G)9MAE, (F/G)9MVT, (F/G)9MVE, (F/G)9MXT, (F/G)8MVL, (F/G)8MTL

NAHB01001LP

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

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.

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 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

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

AVERTISSEMENT

! 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.

Specifications subject to change without notice.

443 06 1522 00 6/12/14

! 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

CONDENSING FURNACES

MODEL NUMBERS BEGINNING WITH:

(F/G)9MAC (F/G)9MVT

(F/G)9MAE (F/G)9MVE

SECTION 1

(F/G)9MXT

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.

This instruction covers the installation of gas conversion kit Part No. NAHB01001LP to convert the following furnaces from natural gas usage to propane gas usage. See appropriate section for your furnace type.

Section 1—(F/G)9MAC, (F/G)9MAE, (F/G)9MVT, (F/G)9MVE, & (F/G)9MXT 35−in. (889 mm ) 4-Way Multipoise, Hot Surface Ignition, Modulating Variable−Speed, Two−Stage Variable−Speed and Two−Stage ECM Blower Motor Condensing Furnaces.

Section 2—(F/G)8MVL & (F/G)8MTL, 33.3−in. (846 mm) High, Induced−Combustion, Hot−Surface Ignition, Two-Stage,

INSTALLATION

1. Set room thermostat to lowest setting or “OFF”.

2. Remove outer doors.

3. Disconnect power at external disconnect, fuse or circuit

breaker.

4. Turn off gas at external shut-off or gas meter.

5. Remove outer doors and set aside.

6. Turn electric switch on gas valve to OFF.

Figure 1

Representative Furnace Drawing

HOT SURFACE IGNITER

GAS BURNER

MANUAL RESET ROLLOUT SWITCH

Variable-Speed, Non-Condensing Furnaces.

FLAME

DESCRIPTION AND USAGE

This kit is designed for use in the furnaces listed below. See Table 1 for kit contents. To accommodate many different furnace models, more parts are shipped in kit than will be needed to complete conversion. When installation is complete, discard extra parts.

Table 1 NAHB01001LP Contents

QUANTITY DESCRIPTION

1 VALVE CVRSN KIT - W/R F92-102100

SENSOR

MANUAL RESET ROLLOUT SWITCH

GAS VALVE

OPERATING INSTRUCTIONS NOT SHOWN (LOCATED ON MAIN FURNACE DOOR, SEE OPERATING INSTRUCTIONS INSIDE DOOR FIGURE).

ELECTRICAL JUNCTION BOX (IF REQUIRED, LOCATION MAY VARY)

BLOWER DOOR SAFETY SWITCH

MAIN LIMIT SWITCH

(BEHIND GAS VALVE)

INDUCER MOTOR ASSEMBLY

2 VALVE CVRSN KIT - W/R SPRING 92-0659

7 ORIFICE - #55

7 ORIFICE - #56

FURNACE CONTROL BOARD

BLOWER AND MOTOR

7 ORIFICE - 1.25mm

7 ORIFICE - 1.30mm

7 SCREW - SPOILER (CONDENSING)

7 SCREW - SPOILER (NON−CONDENSING)

1 CONNECTOR - BRASS 1/8” NPT X2”

1 CONNECTOR,SPLC - 3/16”

1 CONNECTOR-1/4QC ME BOTH ENDS

1 ELBOW, STREET - 150# 1/8” NPT

1 ELBOW, STREET - BRASS 1/8” NPT

RATING PLATE NOT SHOWN

(LOCATED ON BLOWER DOOR)

REPRESENTATIVE DRAWING ONLY, SOME MODELS MAY VARY IN APPEARANCE.

MANIFOLD/ORIFICE/BURNER REMOVAL

CAPACITOR/ POWER CHOKE

L11F045

1 NIPPLE - HEX (BRASS)

1 SWITCH, PRESSURE

1 TEE - MALE BRANCH (BRASS)

1 TEE, STREET - MALE BRANCH (BRASS)

1 BIT, DRILL 7/64” CONDENSING

1 BIT, DRILL 5/64” NON−CONDENSING

2 WIRE ASSY - ORANGE

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.

! CAUTION

1 LABEL 339268-201

1 LABEL 339268-202

PRUDENCE

1 LABEL 339268-203

1 LABEL 339268-204

1 LABEL 339268-205

1 LABEL 339268-206

1 LABEL 339268-209 (FRENCH)

1 LABEL 339268-211 (FRENCH)

1 LABEL 339268-214 (FRENCH)

1 INSTRUCTIONS

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.

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.

2 443 06 1522 00

Specifications subject to change without notice.

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

2. Disconnect the connector harness from gas valve. Disconnect wires from Hot Surface Igniter (HSI) and Flame Sensor.

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

4. Note the location of the green/yellow wire ground wire for re-assembly later. (See Figure 2)

5. Slide one−piece burner assembly out of slots on sides of burner box. (See Figure 3)

6. Remove the flame sensor from the burner assembly.

7. Remove the orifices from the manifold and discard.

Figure 2

Connect Green/Yellow ground wire here

Gas valve is parallel to manifold

within + or - 3˚

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

REPRESENTATIVE DRAWING ONLY, SOME MODELS MAY VARY IN APPREARANCE.

Gas Valve with Orifices

Orifice

Manifold

Gas Valve

Indicated surfaces

˚+ or -2˚

to be 90

Figure 3 Burner Assembly

BURNER SUPT. ASSY

BURNER ASSY

IGNITER

BRACKET, IGNITER

A11486

ORIFICE SELECTION/DERATE

! CAUTION

UNIT DAMAGE HAZARD

Failure to follow this caution may result in unit damage.

DO NOT re−drill burner orifices. Improper drilling may result in burrs, out−of−round holes, etc. Obtain new orifices if orifice size must be changed. (See Figure 4)

Figure 4 Burner Orifice

BURNER ORIFICE

A96249

Refer to conversion kit rating plate 339268−201 or 339268−206 to determine main burner orifice size. (See Figure 6)

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

In the U.S.A.; the input rating for altitudes above 2000 ft. must be reduced by 2 percent for each 1000 ft. above sea level.

In Canada, the input rating must be derated by 5 percent for altitudes of 2000 ft. to 4500 ft. 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 are two sets of mixer screws. One set is for

Condensing gas furnaces, the other set is for Non-condensing gas furnaces. Use only the parts in the bag marked

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

See Figure 5 to verify you have the correct set of mixer screws.

Figure 5

Gas Conversion Kit

FLAME ROLLOUT SWITCH

FLAME SENSOR (BELOW BURNER)

443 06 1522 00 3

Specifications subject to change without notice.

A11403

A11294

1. Locate the dimple on each burner venturi tube. If you cannot locate the dimple, refer to Figure 7 for location of the mixer screw.

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

Figure 6

Conversion Kit Rating Plate − (F/G)9MAC & (F/G)9MAE

Conversion Kit Rating Plate − (F/G)9MVT, (F/G)9MVE & (F/G)9MXT

3. Install a mixer screw in each drilled hole drilling as straight as possible. The screw head should be flush with the top of the burner venturi.

Figure 7 Mixer Screw Location

REINSTALL BURNER ASSEMBLY

To reinstall burner assembly:

1. Attach flame sensor to burner assembly.

2. Insert one−piece burner in slot on sides of burner box and slide burner back in place.

1.9”

(48.76 mm)

Drill out with 7/64” drill bit

3. Reattach HSI wires to HSI.

4. Verify igniter to burner alignment. See Figure 8 and

Figure 9.

Figure 8 Igniter Position − Back View

1.8”

(46.96 mm)

1-1/4-in.

(31.8)

2-1/2-in.

A11460

4 443 06 1522 00

Specifications subject to change without notice.

(64.4)

A11405

Figure 9 Igniter Position − Side View

2 − in. (50 mm)

3/8 − in. (9.6 mm)

3/16− in. (4.6 mm)

(F/G)9MAC & (F/G)9MAE − Modulating Gas Valve

Refer to Figure 10 and Figure 11.

Figure 10

Propane Jumper

3/32− in., +1/32 -3/64-in. (2.5 mm

, +0.8 -1.5)

A12392

CONVERT GAS VALVES

! CAUTION

UNIT DAMAGE HAZARD

Failure to follow this caution may result in unit damage.

The gas valve must be converted and pre−adjusted before operating on propane gas. If not converted and pre−adjusted, sooting and corrosion will occur leading to early heat exchanger failure.

! 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.

! 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.

A11373

Figure 11 Installing Propane Jumper

A11375

NOTE: The Propane jumper for the modulating gas valve is very small. Needle-nose pliers are required to insert the jumper into the valve. If the jumper is not installed, the valve will not operate properly on propane.

1. Locate the round “NAT GAS” sticker on the top of the gas valve.

2. Peel the sticker off and discard.

3. Note the small square opening in the top of the gas valve.

4. Note the two jumper pins inside the modulating gas valve.

5. Remove the small black plastic propane jumper from the envelope.

6. Use needle-nosed pliers to hold the jumper by the tab on the end.

7. Insert the jumper on the pins inside the gas valve.

8. Cover the opening in the gas valve with the label marked

“LP GAS”

443 06 1522 00 5

Specifications subject to change without notice.

Figure 12

Inlet Pressure Tap

(F/G)9MAC & (F/G)9MAE − Redundant Automatic Control Valve (Modulating)

ON/OFF Switch

GAS FLOW

MODULATING

Turn screw 1 click per second to adjust rate. Clockwise to increase rate, counter clockwise to decrease rate.

Min/Max Heat Adust (Under Cap)

INSTALL LOW GAS PRESSURE SWITCH

NOTE: Install the Low Gas Pressure Switch before installing

the manifold on the burner assembly. There are two ways to mount the Low Gas Pressure Switch.

All 14 3/16-in Casings or Vent Passes Between Inducer Assembly and Burner Assembly

If the vent pipe passes between the inducer and burner assembly, or the furnace is a 14 3/16-in. wide casing, install the switch as follows (See Figure 14):

LGPS for 14−3/16 Casing or When Vent

Figure 14

Passes Between Inducer and Burner Assembly

1/2” NPT Outlet

Manifold Pressure Tap

A10496

(F/G)9MVT, (F/G)9MVE & (F/G)9MXT − Two Stage Gas Valve

Refer to Figure 13.

1. Be sure gas and electrical supplies to furnace are off.

2. Remove caps that conceal adjustment screws for high heat and low heat gas−valve regulators. (See Figure 13)

3. Remove the high heat and low heat regulator adjustment screws.

4. Remove the high heat and low heat regulator springs (silver).

5. Install the high heat and low heat propane gas regulator springs (white).

6. Install the high heat and low heat regulator adjustment screws.

7. Turn high heat stage adjusting screw clockwise (in) 13.5 full turns. This will increase the manifold pressure closer to the propane set point.

8. Turn low heat stage adjusting screw clockwise (in) 9.5 full turns. This will increase the manifold pressure closer to the propane low heat set point.

9. Do not install regulator seal caps at this time.

Figure 13

1/2” NPT Inlet

(F/G)9MVT, (F/G)9MVE & (F/G)9MXT − Two −Stage Gas Valve

TWO-STAGE

ON/OFF Switch

Regulator Seal Cap

Regulator Adjustment Regulator Seal Cap under Cap

Black Iron Street 90 Pointing

Low Gas Pressure Switch

Brass Street Tee

Inlet Pressure Tap with

Brass Street 90

Brass Hex Nipple

A11367

1. Remove the 1/8-in. (3 mm) NPT pipe plug from the gas valve inlet pressure tap.

NOTE: Use pipe dope approved for use with Propane Gas. NOTE: Tighten all fittings and the Low Gas Pressure Switch

with a small wrench. Do not over-tighten, check for gas leaks after gas supply has been turned on.

! WARNING

FIRE AND EXPLOSION HAZARD

Failure to follow this warning could result in personal injury and/or death.

NEVER test for gas leaks with an open flame. Use a commercially available soap solution made specifically for the detection of leaks to check all connections. A fire or explosion may result causing property damage, personal injury or loss of life.

AVERTISSEMENT

RISQUE D’EXPLOSION ET D’INCENDIE

Le fait de ne pas suivre cet avertissement pourrait entraîner

1/8” NPT Inlet Pressure Tap

des dommages corporels et / ou la mort. Ne jamais examiner pour les fuites de gaz avec une flamme

vive. Utilisez plutôt un savon fait specifiquement pour la

1/2” NPT Outlet

détection des fuites de gaz pour verifier tous les connections. Un incendie ou une explosion peut entrainer des dommages matériels, des blessures ou la mort.

1/8” NPT Manifold Pressure Tap

A11152

6 443 06 1522 00

Specifications subject to change without notice.

2. Apply pipe dope sparingly to the male threads of the 1/8−in. (3 mm) Black iron street elbow. Install the street elbow into the gas valve inlet pressure tap. Point the open end of the street elbow toward you.

3. Apply pipe dope sparingly to the male threads of the 1/8−in. (3 mm) brass street tee. Install the male end of the street tee as shown in Figure 14. One opening on the street tee should face you. The other opening should be parallel with the inlet of the gas valve.

4. Apply pipe dope sparingly to the male threads of the 1/8−in. (3 mm) brass hex nipple. Install the hex nipple into the open end of the brass street tee. See Figure 14. The hex nipple should be parallel with the boss on the gas valve.

5. Install the open end of the brass street elbow on the end of the hex nipple. Tighten the street elbow so the male threads of the elbow point away from you.

6. Apply pipe dope sparingly to the male threads of the 1/8−in. brass street elbow. Install the Low Gas Pressure Switch on the male threads of the 1/8−in. (3 mm) street elbow. Tighten switch at hex fitting at base of switch. Do not use switch body to tighten switch. Do not over-tighten switch.

7. The remaining opening on the brass street tee is the new gas valve inlet pressure tap. Install manometer fitting to the open end of the brass street tee. Or if installation is to be completed later, apply pipe dope to inlet pressure plug from gas valve and install in open end of brass street tee.

8. Check all fittings for leaks after gas supply has been turned on.

Casings Wider Than 14 3/16-in./Vent Does Not Pass Between Inducer and Burner Assembly

1. If the vent pipe does not pass between the inducer and burner assembly, or the furnace is wider than a 14 3/16-in. wide casing, install the switch as follows (See Figure 15):

2. Remove the 1/8-in. (3 mm) NPT pipe plug from the gas valve inlet pressure tap.

NOTE: Use pipe dope approved for use with Propane Gas. NOTE: Tighten all fittings and the Low Gas Pressure Switch

with a small wrench. Do not overtighten, check for gas leaks after gas supply has been turned on.

3. Apply pipe dope sparingly to the male threads of the 1/8−in. (3 mm) brass street elbow. Install the street

elbow into the gas valve inlet pressure tap. One end of the opening of the street elbow should be parallel with the inlet boss on the gas valve.

4. Apply pipe dope sparingly to the male threads of the 1/8−in. (3 mm) x 2−in. (50.8 mm) brass nipple. Install the

brass nipple into the open end of the brass street elbow.

5. Install the open end of the brass street elbow on the end of the brass nipple. Tighten the street elbow so the male threads of the elbow point away from you.

6. Apply pipe dope sparingly to the male threads of the 1/8−in. brass street elbow. Install the Low Gas Pressure

Switch on the male threads of the 1/8−in. (3 mm) brass street elbow finger tight. Tighten switch at hex fitting at base of switch. Do not use switch body to tighten switch. Do not overtighten switch.

8. Check all fittings for leaks after gas supply has been turned on.

INSTALL LOW GAS PRESSURE SWITCH WIRES

1. Locate the orange wire in the kit with an insulated straight female spade terminal and an insulated straight male terminal on the other end.

2. Connect the female terminal to a terminal on the Low Gas Pressure Switch.

3. Locate the orange wire in kit with an insulated straight female spade terminal and an insulated female flag terminal on the other end.

4. Connect both straight female terminals of the orange wires to the terminals on the Low Gas Pressure Switch.

LGPS for Casing Wider Than 14−3/16

Figure 15

For larger casing when Vent Pipe does not pass across casing. All Sizes switch contacts must point toward the Cell Panel. Black Iron Street 90 can be used at Valve Inlet instead of Brass Street 90.

Inlet Pressure Tap with Plug

Low Gas Pressure Switch

and Vent Does Not Pass Between Inducer and Burner Assembly

Brass Street Tee

Brass Street

Brass Nipple

A11366

INSTALL MANIFOLD

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

2. 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.

3. Attach the green/yellow wire and ground terminal to one of the manifold mounting screws.

4. Install the remaining manifold mounting screws.

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

6. Connect the connector harness to gas valve

NOTE: Use only propane−resistant pipe dope. Do not use Teflon tape.

7. Insert the gas pipe through the grommet in the casing. Apply a tin 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.

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

9. Turn gas on at electric switch on gas valve.

MODIFY PRESSURE SWITCH WIRING

! 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.

! PRUDENCE

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.

443 06 1522 00 7

Specifications subject to change without notice.

+ 15 hidden pages