Installation Instructions For Natural Gas Conversion
(Kit Part No. 1173865)
This kit is designed for conversion to Natural Gas.
Natural Gas Orifice Kits and Sizes
Elevation Above Sea Level
Table 1
0 to 2000 ft
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 #
Orifice Drill #
Orifice Drill #
Orifice Drill #
Orifice Drill #
Orifice Drill #
Orifice Drill #
Model Number
PGAA, PGMD (All Sizes)
Orifice Drill #
Kit Number
1173863
(Field-Supplied) (Field-Supplied) (Field-Supplied) (Field-Supplied) (Field-Supplied) (Field-Supplied) (Field-Supplied)
44
44
44
44
44
44
41
42
42
44
44
44
41
42
42
45
45
45
45
45
45
43
43
43
45
45
45
43
43
43
46
46
46
46
46
46
43
43
43
46
46
46
43
43
43
47
47
47
47
47
47
43
44
44
47
47
47
43
44
44
47
47
47
47
47
47
44
44
44
47
47
47
44
44
44
48
48
48
48
48
48
44
45
45
48
48
48
44
45
45
48
48
48
48
48
48
45
46
46
48
48
48
45
46
46
49
49
49
49
49
49
46
47
47
49
49
49
46
47
47
PGAD, PGME (All Sizes)
1173863
1173863
1173863
1173863
1173863
1173865
1173865
1173865
1173863
1173863
1173863
1173865
1173865
1173865
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
44
44
44
41
42
42
44
44
44
41
42
42
1173863
1173863
1173863
1173865
1173865
1173865
1173863
1173863
1173863
1173865
1173865
1173865
45
45
45
43
43
43
45
45
45
43
43
43
46
46
46
43
43
43
46
46
46
43
43
43
47
47
47
43
44
44
47
47
47
43
44
44
47
47
47
44
44
44
47
47
47
44
44
44
48
48
48
44
45
45
48
48
48
44
45
45
48
48
48
45
46
46
48
48
48
45
46
46
49
49
49
46
47
47
49
49
49
46
47
47
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 input rate at 4% per 1000 feet above sea level for altitudes exceeding 2000 feet above sea level.
Natural gas data is based on .60 specific 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 Natural 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.
Parts List, Kit # 1173865
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.
Description
Part #
Qty
7
Burner Orifice #41
1096942
1011351
Burner Orifice #42
7
Pilot Orifice (0.018)
Honeywell Conv. Kit #396222
Label, Natural Gas Conversion
Label, Field Conversion
Instructions
503211
1172952
1
1
1173866
1
1009678
1
462 06 1211 00
1
SAFETY REQUIREMENTS
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.
!
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.
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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-- 1 --
Disassembly
Figure 2
Installing NOx Baffles
Refer to Figure 1 and the following steps.
Disassembly
Figure 1
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 re-
place them with the proper orifice size for the specific fur-
nace model, input size, and altutude from table 1.
Changing Orifices
Figure 3
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.
3
2. Tighten the orifices so they are 1 / ″ from the face of the
16
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.
462 06 1211 00
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-- 3 --
Figure 4
Figure 6
Burner Pilot Assembly
Manifold/Orifice Measurement
3
Measure 1 /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)
Gas Valve Conversion (Required for Converting
from Propane Gas to Natural Gas)
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.
Conversion of Honeywell VR8200, SV9500, SV9501 and
VR8204M Gas Valves using Natural Gas Conversion Kit #
396222.
Changing Pilot Orifice
Figure 5
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.
Typical Gas Valve Honeywell
SV9500
Figure 7
Pilot
Orifice
Inlet Pressure
Tap (Hidden)
Wiring
Terminals
ON
OFF
Honeywell
WARNING
Explosion Hazard.
Serious injory or death
can result.
IGNITER
Read instructions before
operating valve.
Never
operate valve
use tools to
disassemble valve. call
a
qualified service technician
.
if the appliance does not
Pilot
Outlet
Do not
function properly.
CONTROL
INLET
OUTLET
Pilot Adjustment
Outlet Pressure Tap
25-50-06
Connect manometer here to
check outlet pressure. Must be
adjusted per Table 1.
462 06 1211 00
3/17/06
-- 4 --
4. Install the pressure regulator adjusting screw. This will set
the manifold pressure close to required setting for normal
operation.
Typical Gas Valve Honeywell
SV9501
Figure 8
Wiring Terminals
5. Replace the regulator cap screw.
Inlet Pressure
Tap (Hidden)
6. Attach gas valve conversion label (found in Honeywell con-
version 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.
INLET
Pilot
Outlet
D
D
Manifold Assembly -- Be sure to engage the main burner
orifices in the proper openings in the burners.
Pilot
Adjustment
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.
OUTLET
Outlet Pressure Tap
Start--up and Check--out
Connect manometer here to
check outlet pressure. Must be
adjusted per Table 1.
25--22--25
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
Table 2 for proper supply pressure values. If not within
these limitations DO NOT OPERATE UNIT, contact gas
supplier.
Typical Gas Valve Honeywell
Figure 9
VR8205S
Regulator Adjustment
Under Cap
Outlet
HONEYWELL
3. Close manual gas line valve to unit, remove manometer and
replace inlet pressure tap plug.
Pressure
Tap
1
/ NPT
8
Gas Valve Adjustment
V
T
INLET
4. With the gas valve knob in the OFF position, remove the
pressure tap plug from the outlet end of the valve, and con-
nect a “U” tube manometer to the pressure port. (See Fig-
ure 7, 8, 9 & 10).
OUTLET
Inlet
ON
Pressure
1
Tap / NPT
5. Turn the gas valve knob to the ON position and restore elec-
trical 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.
8
OFF
25--24--98a
Typical Honeywell
Regulator Assembly
Figure 10
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”.
LP
Natural
Gas
Silver
Gas
Cap Screw
Black
Pressure
Regulator
Adjusting
Screw
White White
7. Turn gas valve to OFF. Remove the pressure gauge and re-
place the pressure tap plug and pressure regulator cap
screw.
Stainless
Steel
8. With gas valve on, observe furnace through two or more
complete cycles to be sure all controls are operating.
Spring
Red
PRESSURE
REGULATOR
HOUSING
462 06 1211 00
3/17/06
-- 5 --
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.
FIRE AND/OR EXPLOSION HAZARD
Failure to follow this warning could result in personal
injury, death, and/or property damage.
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.
Do NOT attempt to light the burner with a match or
flame of any kind.
HEATING INPUT RATE CHECK
Example: Assume that the size of the meter dial is 1 cu. ft.,
one revolution takes 44 seconds, and the heating value of
the gas is 1020 Btu/ft3. Proceed as follows:
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. 38 sec. To complete 1 revolution
2. 3600/38 = 94.7
3. 94.7 x 1 = 94.7
1. Turn off all other gas appliances that use the same
meter.
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).
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.
Required Input Rate for All Models
Required Input Rate of Furnace Converted to Natural Gas (Btu/hr)
Table 3
Elevation Above Sea Level (feet)
Heating Model
Size1
0-2000
2001-3000 3001-4000 4001-5000 5001-6000 6001-7000 7001-8000 8001-9000 9001-10000
"040" or "B"
"060" or "C"
"080" or "D"
"100" or "E"
"120" or "F"
"140" or "G"
1Note:
40,000
60,000
35200
52800
70400
88000
105600
123200
33600
50400
67200
84000
100800
117600
32000
48000
64000
80000
96000
112000
30400
45600
60800
76000
91200
106400
28800
43200
57600
72000
86400
100800
27200
40800
54400
68000
81600
95200
25600
38400
51200
64000
76800
89600
24000
36000
48000
60000
72000
84000
80,000
100,000
120,000
140,000
For PGF3, PGX3, and PDX3 models, heating model size is indicated by the numbers in the 5th, 6th, and 7th characters in the model number.
For PGF, PGC, PGS models, heating model size is indicated by the numbers in the 8th, 9th, and 10th characters in the model number.
For GPFM, GPCM, and GPSM models, heating model size is indicated by the numbers in the 8th, 9th, and 10th characters in the model number.
For PGAA, PGAD, PGCA, and PGCD models, heating model size is indicated by the letter in the 7th character in the model number.
For PGMD and PGME models, heating model size is indicated by the letter in the 7th character in the model number.
462 06 1211 00
3/17/06
-- 6 --
Pilot Burner Flame Check (All models Main Burner Flame Check
except PGF3, PGX3, and PDX3)
Check for the following:
3
1
Adjust flames so they surround / ″ (9 mm) to / ″ (13 mm) of the
8
2
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.
sensor tip (See Figure 11).
1. Remove the cap from the pilot adjusting screw (See Fig-
ures 7 & 8).
D
D
Flames extending directly from burner into heat exchanger.
Flames DO NOT touch sides of heat exchanger
2. Turn pilot adjusting screw counterclockwise to increase,
clockwise to decrease.
Figure 12
Main Burner
3. Replace the cap on the pilot adjusting screw.
BLUE FLAME
Figure 11
Pilot Burner (HSP)
Sensor Tip
Proper Flame
Adjustment
Hot Surface
Igniter
25--00--07a
1 0 -- 11 -- 6 5
462 06 1211 00
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-- 7 --
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