Honeywell PGF3 User's Manual
Contents
1. Figure 7 Typical Gas Valve Honeywell SV9500 Inlet Pressure Tap Hidden Wiring Terminals l y n eo M J Y P OUTLET Pilot Adjustment e ip Outlet Pressure Tap Connect manometer here to check outlet pressure Must be adjusted per Table 1 25 50 06 462 06 1211 00 3 17 06 3 4 Install the pressure regulator adjusting screw This will set Figure 8 Typical Gas Valve Honeywell the manifold pressure close to required setting for normal SV9501 operation Wiring Terminals 5 Replace the regulator cap screw Inlet Pressure 6 Attach gas valve conversion label found in Honeywell con Tap Hidden 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 e Manifold Assembly Be sure to engage the main burner orifices in the proper openings in the burners e 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 Start up and Check out check outlet ina Must be 25 22 25 1 Remove the plug from the Inlet Pressure Tap on gas valve adjusted per Table 1 and install a manometer See Figures 7 8 9 amp 10 2 Open manual gas line valve to unit Check for gas leaks and Typical Gas Valve Honeywell correct as neces2. Installation Instructions For Natural Gas Conversion Kit Part No 1173865 This kit is designed for conversion to Natural Gas Table 1 pom Dip AT Orifice Drill Orifice Drill Orifice Drill Orifice Drill Orifice Drill Orifice Drill Orifice Drill Field Supplied Field Supplied Field Supplied Field Supplied f Field Supplied f Field Supplied Field Supplied POARPGMDIATSwes TS E Sw eee SEAS E E a a E L a a C E E a L L L a a a E oS E E a a E L C EES A A L S S E S S SCOT SCOT CT a S S E E E E L S S pew ena f e f os e y e f a f a f a y a a C A EE Oe a E ees 8 7 8 PGF FSKOGOF GPFMPKOG ES e o o a e f e C S E f SPST SCOT COT CTC CY PGFFKIOOF GPFMPKIO Oa me EE f o f u f a e f H PGFPEKIZOF GPFWPKID Oe me s e ua 6 7 PoreKIMO GrFMKIAD sess Sa CTS CE CC CT CT CS L CSCS AS ES A A E PosmKoe0r GrsweKos L Snes E E L OTC a a CY C S E SPCC COUT a perena f o f oe e f e f oa S a f a y H y o POSKO GPSNEKII D E E E L L a L ea SS E ES ET L L L mro S a S Ce e y e o o y a f a y a mro ooo f a S o e y e o CTC a f a f a mso ooo f oa S es e y e S a a y a f e y e e E e See A o re e e f a l a e a l o 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 ex
3. Check for the following Adjust flames so they surround 3 8 9 mm to 1 2 13 mm of the e Stable and blue flames See Figure 12 Dust may cause sensor tip See Figure 11 orange tips or wisps of yellow but flames MUST NOT have 1 Remove the cap from the pilot adjusting screw See Fig solid yellow tips ures 7 amp 8 e Flames extending directly from burner into heat exchanger 2 Turn pilot adjusting screw counterclockwise to increase e Flames DO NOT touch sides of heat exchanger clockwise to decrease 3 Replace the cap on the pilot adjusting screw Figure 11 Pilot Burner HSP Sensor Tip Proper Flame Adjustment Hot Surface Eaa Igniter 10 11 65 462 06 1211 00 7 3 17 06
4. UIREMENTS 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 Understand the signal words DANGER WARNING or CAUTION Start up and adjustment procedures and service calls 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 Recognize safety information This is the safety alert siba N When you see this symbol in instruction manuals be alert to the potential for personal injury 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 qe 3 17 06 Import
5. ample 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 1 38 sec To complete 1 revolution 2 3600 38 94 7 3 94 7 x 1 94 7 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 Table 3 Heating Model Se oao Jar Required Input Rate for All Modas aor For PGF 3 PGX3 and PDX3 models heating model size is indicated by the numbers in the 5 6 and 7 characters in the model number For PGF PGC PGS models heating model size is indicated by the numbers in the 8 9 and 10 characters in the model number For GPFM GPCM and GPSM models heating model size is indicated by the numbers in the 8 9 and 10 characters in the model number For PGAA PGAD PGCA and PGCD models heating model size is indicated by the letter in the 7 character in the model number For PGMD and PGME models heating model size is indicated by the letter in the 7 character in the model number 9001 24000 36000 48000 60000 72000 84000 EJEN 462 06 1211 00 3 17 06 Pilot Burner Flame Check All models Main Burner Flame Check except PGF3 PGX3 and PDX3
6. ant Information This kit includes a Honeywell conversion kit for converting Honeywell VR8200 VR8205S SV9500 SV9501 or VR8204M gas valves certified for use with Propane Gas and so marked to units functionally the same as the certified furnace for use with Natural Gas If converting from propane gas to natural gas the gas valve conversion kit main burner orifices and pilot orifice all found in this kit must be installed For converting the furnace from standard altitude on natural gas to high altitude 2001 feet above sea level or greater on natural gas the Honeywell conversion kit and pilot orifice changes are not needed Only the main burner orifices require changing Refer to Table 1 for proper orifice size for specific model number input capacity and installation altitude The orifices provided in this kit are stamped to indicate the size twist drill number and are sized for natural gas ONLY Do NOT use them with butane or a mixture of butane and propane 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 especially if the venting is inadequate For that reason we recommend that the installer check the size of the orifice with a new twist drill o
7. 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 3 17 06 Figure4 Manifold Orifice Measurement Measure 13 16 from face of orifice to back edge of manifold pipe 80 31 34 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 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 Pilot Orifice 25 22 17 Figure 6 Burner Pilot Assembly POSITION DOWEL ON PILOT IN HOLE ON PILOT MOUNTING BRACKET SMS 3 REQ D BRACKET PILOT TIGHTEN FERRULE GAS TIGHT DO NOT BEND PILOT BRACKET Gas Valve Conversion Required for Converting from Propane Gas to Natural Gas Conversion of Honeywell VR8200 SV9500 SV9501 and VR8204M Gas Valves using Natural Gas Conversion Kit 396222 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
8. ceeding 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 2223 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 P art 330732 401 is required for proper conversion For all models except PGX3 PDX3 and PGF3 a 018 pilot orifice P art 5032110 is also required Parts List Kit 1173865 Installing and servicing heating equipment can be hazardous due Description Part Qty to gas and electrical components Only trained and qualified Burner Orifice 41 1096942 7 personnel should install repair or service heating equipment Burner Orifice 42 1011351 7 Untrained service personnel can perform basic maintenance Pilot Orifice 0 018 503211 1 functions such as cleaning and replacing air filters All other Honeywell Conv Kit 396222 1172952 1 operations must be performed by trained service personnel When Label Natural Gas Conversion 1173866 1 working on heating equipment observe precautions in the aren Floid Conversion 462 beats 1 literature on tags and on labels attached to or shipped with the appliance and other safety precautions that may apply SAFETY REQ
9. crew screw ane 8 With gas valve on observe furnace through two or more tee complete cycles to be sure all controls are operating 462 06 1211 00 5 3 17 06 A WARNING FIRE AND OR EXPLOSION HAZARD Failure to follow this warning could result in personal injury death and or property damage Do NOT attempt to light the burner with a match or flame of any kind HEATING INPUT RATE CHECK 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 Turn off all other gas appliances that use the same meter 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 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 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 Ex
10. f the correct size This procedure assures that the orifices provided are the correct size A WARNING ELECTRIC SHOCK HAZARD FIRE AND OR EXPLOSION HAZARD Failure to follow this warning could result in equipment damage personal injury death and or property damage The gas supply shall be shut OFF prior to disconnecting the electrical power before proceeding with the conversion Turn OFF electric power supply at disconnect switch or service panel before starting installation e Shut off gas supply to furnace at manual shut off valve be fore starting installation A WARNING EXPLOSION HAZARD Failure to follow this warning could result in personal injury death and or property damage If unit is still running allow 2 5 minutes after gas shut off before turning off power Shut Off electric power at unit disconnect and service panel e Disconnect electric power supply to the furnace before starting installation e Check for gas leaks after installation of kit and before at tempting to start furnace e Locate the Natural Gas Conversion Label next to the fur nace rating plate e Filloutand attach the Field Conversion Label to the front ex terior of the furnace A WARNING FIRE EXPLOSION CARBON MONOXIDE POISONING HAZARD Failure to follow these instructions exactly could result in personal injury death and or property damage This conversion kit shall be installed by a qualified service agency i
11. n 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 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 the manufacturer s instructions supplied with the kit Gas Pressure e Refer to the furnace rating plate for the approved gas input rating e Gas input to burners MUST NOT exceed the rated input shown on rating plate e Do NOT allow minimum gas supply pressure to vary down ward Doing so will decrease input to furnace Refer to Table 2 for gas supply and manifold pressures Table 2 Gas Supply Pressure Manifold Type Pressure Installation A WARNING ELECTRIC SHOCK HAZARD FIRE AND OR EXPLOSION HAZARD Failure to follow this warning could result in property damage equipment damage personal injury and or death Gas Pressures manual gas valve Turn OFF gas supply at before turning OFF electric power supply and starting installation Turn OFF electric power supply at disconnect switch or before starting installation service panel 462 06 1211 00 3 17 06 Disassembly Refer to Figure 1 a
12. nd the following steps Figure 1 Disassembly Manifold Support Bracket Manifold Support Bracket After shutting off gas supply and electric power to the unit remove the access door exposing gas valve and burner compartment Disconnect gas line from gas valve so manifold assembly can be removed Disconnect wiring at gas valve Be sure to note the proper location of any and all electrical wiring disconnected If converting from Propane Gas to Natural Gas remove the pilot supply line from the gas valve Remove the four 4 screws holding the manifold and gas valve to the manifold supports Do Not discard any screws Carefully remove the manifold assembly 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 Installing NOx Baffles 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 Tighten the orifices so they are 13 1 from the face of the orifice to the
13. sary Check supply pressure Refer to VR8205S Table 2 for proper supply pressure values If not within f these limitations DO NOT OPERATE UNIT contact gas Regulator Adjustment supplier Under Cap Outlet l HONEYWELL Pressure 3 Close manual gas line valve to unit remove manometer and 4 With the gas valve knob in the OFF position remove the pressure tap plug from the outlet end of the valve and con Tap replace inlet pressure tap plug O NPT Gas Valve Adjustment II INLET niet 2 OUTLET nect a U tube manometer to the pressure port See Fig Pie ure 7 8 9 amp 10 ressure Tap g NPT 5 Turnthe gas valve knob to the ON position and restore elec O 25 24 98 trical power to unit Cycle the main burner on and off several 24 98a fn times to stabilize the pressure regulator diaphragm This MUST be done before an accurate pressure reading can be obtained 6 Withthe main burner on read the pressure gauge Manifold Natural pressure should be adjusted to values from Table 2 Turn Gas pressure regulator adjusting screw clockwise to increase or Cap Screw Silver counterclockwise to decrease manifold pressure Burner Input must not exceed nameplate rating Refer to Section Pressure White Checking Input Rate Regulator 7 Turn gas valve to OFF Remove the pressure gauge and re Adjusting place the pressure tap plug and pressure regulator cap S
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