Johnson Controls S1-1NP0703 Installation Manual
ACCESSORY KIT INSTALLATION MANUAL
PROPANE CONVERSION – MODEL: S1-1NP0703
FOR USE WITH SINGLE PACKAGE GAS/ELECTRIC UNITS
SERIES: PCG*A and PHG*A
!
WARNING
This conversion kit shall be installed by a qualified service agency in accordance with these 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 these instructions supplied with the kit.
!
CAUTION
The conversion of new certified central heating gas appliances must conform to directions outlined in this instruction. Installation
must be made in accordance with American National Standard National Fuel Gas Code, ANSI Z223.1 — latest edition, unless
superseded by local codes.
For Canadian installations, the conversion shall be carried out in accordance with the requirements of the Provincial authorities
having jurisdiction and in accordance with the CAN1-B149.1 and.2 installation codes.
The manufacturer accepts no responsibility for malfunctions due to improper conversions.
GENERAL
This kit is intended for the conversion of new equipment only.
The kit is for converting the unit from natural gas to propane gas
operation at altitudes below 2,000 feet.
All unit installations above 2,000 feet (610 meters) require an
additional kit installation which contain labels and instructions.
Field furnished orifices must be purchased from Source 1 parts
department.
The instructions in this manual cover the gas conversion of the
unit when it is equipped with a White Rodgers gas valve. The
Installation Instructions supplied with the unit is to be used for
all other aspects of the unit installation.
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WARNING
Improper installation, adjustment, service or maintenance
can cause injury or property damage; therefore, only a qualified installer or qualified service personnel should perform
this conversion.
IMPORTANT
These instructions are for the use of qualified individuals specially trained, experienced and certified in the installation of
this type of equipment and related systems components.
Installation and service personnel are required by some
states to be licensed. Persons not qualified shall not install
this equipment nor interpret these instructions.
This is a safety alert symbol. When you see this symbol on
labels or in manuals, be alert to the potential for personal
injury.
Understand and pay particular attention to the signal words
DANGER, WARNING, or CAUTION.
DANGER indicates an imminently hazardous situation, which, if
not avoided,
WARNING indicates a potentially hazardous situation, which, if
not avoided,
CAUTION indicates a potentially hazardous situation, which, if
not avoided
used to alert against unsafe practices and hazards involving
only property damage.
DESCRIPTION PART NUMBER QTY
Propane Gas Burner Orifice, #54 029-26831-000 4
Gas Line Pressure Switch 024-27688-001 1
Tapped Gas Pipe Nipple 029-22152-000 1
Wire Harness 025-47185-000 1
White Rogers 36J Valve Spring Kit 025-25463-000 1
Label, Propane Conversion 035-24122-001 1
Accessory Kit Installation Manual 035-24605-001 1
Wire Tie 025-27642-000 1
An overpressure protection device, such as a pressure regulator, which conforms to the National Fuel Gas code, ANSI
Z223.1 (U.S.) or CAN-B149.1 or.2 (Canada) and acts to limit
the downstream pressure to value that does not exceed 0.5
PSI (14" w.c.), must be installed in the gas piping system
upstream of the furnace. Failure to do so may result in a fire
or explosion or cause damage to the furnace or some of its
components.
will result in death or serious injury.
could result in death or serious injury.
may result in minor or moderate injury. It is also
CONTENTS OF KIT
!
WARNING
Johnson Controls Unitary Products 035-24605-001-A-0316
035-24605-001-A-0316
FURNACE CONVERSION
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CAUTION
The gas supply shall be shut off prior to disconnecting the
electrical power before proceeding with the conversion.
NOTICE
Do not remove the Low NOx screens from the heat
exchanger tubes.
1. Shut off gas supply at shutoff valve upstream of the unit or
at meter as required.
2. Remove the access panel to the gas heat compartment.
3. Carefully remove the wires from the gas valve, and note
their location so they may be properly replaced. Remove
the screws that hold the manifold to the manifold brackets,
and slide the manifold off the burners.
4. Remove the main burner orifices from the manifold, and
retain for future use.
5. Install the propane main burner orifices in the manifold, and
tighten them. After installing a propane orifice in each location, any leftover orifices may be discarded.
6. Reinstall the manifold in the assembly by reversing the
removal process.
7. Reconnect the wires to the proper terminals on the gas
valve.
8. When installing gas piping, insert tapped gas pipe nipple
(supplied with kit) into inlet fitting of gas valve. Tighten until
the 1/8 inch tapped hole in the gas pipe nipple is located in
the side facing outward toward where the door is to be
installed.
9. Install (thread) the gas line pressure switch (supplied with
kit) into the 1/8 NPT tapped hole in nipple applying pipe
joint compound to the switch fitting prior to installation.
Using a 7/16 inch open end wrench, tighten the switch making sure the connection does not leak. Electrical connections should be facing the right.
10. Rotate the tapped gas pipe nipple a 1/4 turn so the pressure switch is positioned on top of the gas pipe. Refer to
Figure 1.
NOTICE
The gas line pressure switch will cause the furnace to lock
out if the gas supply pressure drops below 6” w.c. The ignition control will display a fault code 7 and will reset after one
hour.
11. Disconnect the wire from the flame sensor.
12. Using the wire harness (supplied with kit) connect the wire
from the flame sensor into the insulated male connector;
connect the two 1/4” insulated terminals to the pressure
switch; and connect the remaining insulated flag terminal to
the flame sensor.
13. Convert the gas valve for LP (propane) gas operation by
following the instructions and using the components supplied in the envelope. Apply the label supplied in the kit to
the gas valve to show that it has been converted.
14. Ensure that all gas connections are tight.
15. Turn on gas supply to unit, and check all gas connections
with suitable leak detector.
16. Install the propane gas conversion label as described in the
LABELS section of this instruction.
17. Refer to the unit installation instructions to complete the
installation before continuing with these procedures.
LABELS
1. Remove conversion rating plate label from the shipping
box.
2. On the gas appliance conversion label, write the following:
a. Kit number, located on the outside of the kit box.
b. Stamp or write in the name of the organization making
conversion, address, city, state, month, and year.
3. Remove label backing, and affix label adjacent to the rating
plate.
FIGURE 1: Tapped Gas Pipe Nipple
2 Johnson Controls Unitary Products
A0243-001
035-24605-001-A-0316
TESTS AND ADJUSTMENTS
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DANGER
PROPANE AND HIGH ALTITUDE CONVERSION KITS
Make sure that the correct kit and/or gas orifices for the altitude and the type of gas is used for the furnace installation.
Only use natural gas in furnaces designed for natural gas.
Only use propane (LP) gas for furnaces that have been properly converted to use propane (LP) gas. Do not use this furnace with butane gas.
Incorrect gas orifices or a furnace that has been improperly
converted will create an extremely dangerous condition
resulting in premature heat exchanger failure, excessive
sooting, high levels of carbon monoxide, personal injury,
property damage, a fire hazard and/or death.
High altitude and propane (LP) conversions are required in
order for the appliance to satisfactorily meet the application.
An authorized distributor or dealer must make all gas conversions.
In Canada, a certified conversion station or other qualified
agency, using factory specified and/or approved parts, must
perform the conversion.
The installer must take every precaution to insure that the furnace has been converted to the proper gas orifice size when
the furnace is installed. Do not attempt to drill out any orifices
to obtain the proper orifice size. Drilling out a gas orifice will
cause misalignment of the burner flames, causing premature
heat exchanger burnout, high levels of carbon monoxide,
excessive sooting, a fire hazard, personal injury, property
damage and/or death.
the manometer, as it will reference atmospheric pressure. Refer
to Figure 2 for inlet pressure port location.
1. Turn gas and electrical supplies on, and follow the operating instructions to place the unit back in operation.
TABLE 1: Inlet Gas Pressure Range
INLET GAS PRESSURE RANGE
Natural Gas Propane (LP)
Minimum 4.5” W.C. (1.12 kPa) 8.0” W.C. (1.99 kPa)
Maximum 10.5” W.C. (2.61 kPa) 13.0” (3.24 kPa) W.C.
IMPORTANT
The inlet gas pressure operating range table specifies what
the minimum and maximum gas line pressures must be for
the furnace to operate safely.
The gas line pressure
• 7” W.C. (1.74 kPA) for Natural Gas
• 11” W.C. (2.74 kPA) for Propane (LP) Gas
in order to obtain the BTU input specified on the rating plate
and/or the nominal manifold pressure specified in these
instructions and on the rating plate.
2. Once the correct gas inlet pressure has been established,
refer to Table 1, turn the gas supply to OFF, and turn the
electrical supply switch to OFF; then remove the flexible
tubing from the gas valve pressure tap, and tighten the set
screw using the 3/32” (2.4 mm) hexagonal wrench.
3. Turn the electrical and gas supplies back on, and with the
burners in operation, check for gas leakage around the gas
valve pressure port for leakage using an approved non-corrosive gas leak detection fluid, or other non-flammable leak
detection methods.
MUST BE a minimum of
Inlet and manifold gas pressure may be measured by connecting the “U” tube manometer to the gas valve with a piece of tubing. Follow the appropriate section in the instructions below.
Refer to Figure 2 for the locations of the pressure ports on the
gas valve.
Turn gas off at the ball valve or gas cock on gas supply line
before the gas valve. Find the pressure ports on the gas
valve marked Out P and In P.
1. The manifold pressure must be taken at the port marked
OUT P.
2. The gas inlet line pressure must be taken at the port
marked IN P.
3. Using a 3/32” (2.4 mm) hexagonal wrench, loosen the set
screw by turning it 1 turn counter clockwise. DO NOT
REMOVE THE SET SCREW FROM THE PRESSURE
PORT.
Read the inlet gas pressure
Connect the positive side of the manometer to the IN P Tap on
the gas valve. Do not connect any tubing to the negative side of
Read the manifold gas pressure
Connect the positive side of the manometer to the OUT P Tap
on the gas valve. Do not connect any tubing to the negative
side of the manometer as this is the port where it references
atmospheric pressure. Refer to Figure 3 for connection details.
IMPORTANT
The cover screw for the pressure regulator must be removed
entirely to gain access to the adjustment screw. Loosening or
tightening the cover screw does not adjust the flow of gas.
1. Refer to Figure 2 for location of pressure regulator adjustment cap, and adjustment screw on main gas valve.
2. Turn gas and electrical supplies on, and follow the operating instructions to place the unit back in operation.
3. Adjust manifold pressure by adjusting gas valve regulator
screw for the appropriate gas per the following:
Johnson Controls Unitary Products 3
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