hang06 halp05 hacips01-10 io manual
Contents
1. A HANGO6 High Altitude Natural Gas installation This conversion kit shall be installed by instructions orifices wire ties a eee agency T oeorcane w ih HALPO5 High Altitude Propane installation instruc the manufacturer s instructions and all tions propane orifices valve conversion kits with applicable codes and requirements of instructions conversion rating plate conversion the authority having jurisdiction If the date certificate wire ties and screen turbulator infomation in these instructions is not removal warning tag followed exactly a fire explosion or pro HAC1PS High Altitude Catagory 1 Pressure Switch duction of carbon dioxide may result installation instructions pressure switch causing property damage personal in jury or loss of life The qalified service agency performing this work assumes responsibility for the proper conversion of this appliance with this kit Amana Refrigeration Inc Effective October 1994 Fayetteville TN 37334 10759901 I DESCRIPTION These kits are required when installing Amana Air Com mand 80 SSE and SV furnaces GUIA GCIA GUIB and GCIB at altitudes above 7500 ft Above this altitude a derating of the appliance must be followed since the CFM moved by the induced draft and blower fans remain almost constant while the pounds of oxygen in that air is reduced as the altitude increases If this procedure is not followed and the fuel input is not reduced2. Amana A Raytheon Company HANGO6 HALPO5 amp High Altitude Conversion HAC1PS01 thru 10 Kits Installation Instructions ATTENTION INSTALLING PERSONNEL As a professional installer you have an obligation to Remember it is your responsibility to install the know the product better than the customer This product safely and to know it well enough to be able includes all safety precautions and related items to instruct a customer in its safe use Prior to actual installation thoroughly familiarize Safety is a matter of common sense a matter of yourself with this Instruction Manual Pay special thinking before acting Most dealers have a list of attention to all safety warnings Often during instal specific good safety practices follow them lation or repair it is possible to place yourself in a position which is more hazardous than when the unit The precautions listed in this Installation Manual is in operation should not supersede existing practices but should be considered as supplemental information Myzecocnzzz THIS SYMBOL AS A SAFETY PRECAUTION THE INSTALLATION AND SERVICING OF THIS EQUIPMENT SHOULD BE PERFORMED ONLY BY QUALI FIED EXPERIENCED TECHNICIANS IN CANADA THE CONVERSION SHALL BE CARRIED OUT IN ACCORDANCE WITH THE REQUIREMENTS OF THE PROVINCIAL AUTHORITIES HAVING JURISDICTION AND IN ACCORDANCE WITH THE REQUIRE MENTS OF THE CAN CGS B149 1 AND B149 2 INSTALLATION CODE Kit Includes A WARNING
3. IOUS PERSONAL INJURY OR DEATH Aywarnine PERSONAL INJURY HAZARD iron oxide rust can reduce the level of odorant in propane gas A gas detecting device is the only reliable method to detect a propane gas leak Contact your propane supplier about installing a gas detecting warning device to alert you in the event that a gas leak should develop Failure to detect a propane gas leak could result in an EXPLOSION or FIRE which could cause SERIOUS PERSONAL INJURY OR DEATH h caution To prevent unsatisfactory furnace op eration the proper gas conversion kit must be used for each valve Use the White Rodgers spring kit only with the White Rodgers gas valve and use the Honeywell spring kit only with the Hon eywell gas valve THE SPRING KITS ARE NOT INTERCHANGEABLE IMPORTANT Propane gas is heavier than air and does not vent upward as with natural gas fuels 1 IMPORTANT Remove the metal inserts from the entrance of all heat exchanger tubes as shown in Fig 4 This should be done as part of the ORIFICE INSTALLATION procedure 2 Replace the gas valve regulator spring with one of two new springs included in this propane gas conver MANIFOLD PRESSURE ADJUSTMENT MANIFOLD PRESSURE TAP FIGURE 5B WHITE RODGERS SPRING KIT V OPERATIONAL CHECK 1 Start the furnace using the procedures in the section Operating Your Furnace in the installation instruc tions In addition pe
4. ON PANEL RETENTION PLATE BURNER BOX ASSY SCREEN INSERTS FIGURE 4 REMOVAL OF METAL SCREEN INSERTS a Remove entire burner box assembly including bumers from the partition panel as one unit D Hold assembly and remove the screen retention plate and tube inserts from each section of the heat exchanger Q Reinstall the retention plate and entire bummer box assembly 6 Reinstall the gas manifold and reconnect the gas valve low voltage wiring Install new wire ties making sure that wires do not droop between orifices and burners 7 If converting to propane gas see PROPANE GAS CONVERSION section for additional instructions If remaining on natural gas skip to OPERATIONAL CHECK IV PROPANE GAS CONVERSION Aywarnine PERSONAL INJURY HAZARD If your propane gas furnace is installed in a basement an excavated area or a confined space we strongly recommend that you contact your propane supplier about installing a warning device that would alert you to a gas leak Propane gasis heavier than airand any leaking gas can settle in any low areas or confined spaces Propane gas odorant may fade mak ing the gas undetectable except with a warning device An undetected gas leak would create a danger of explosion or fire If you sus pect the presence of gas follow the in structions on the cover of the furnace installation manual Failure to do so could result in SER
5. and 14 0 inches of water CHECK THE MANIFOLD PRESSURE A tapped opening Manifold Pressure Tap in Fig ures 5A or 6A is provided in the gas valve to facilitate measurement of the manifold pressure A U Tube manometer having a scale range from 0 to 12 inches of water should be used for this measurement The manifold pressure must be measured with the burn ers operating and the burner box cover in place To adjust the pressure regulator remove the adjust ment screw or cover on the gas valve Turn out counterclockwise to decrease pressure turn in clockwise to increase pressure Manifold Pressure Adjustment in Figs 5A or 6A Only small variations in gas flow should be made by means of the pressure regulator adjustment For natural gas the manifold pressure must be between 3 2 and 3 8 inches water column 3 5 nominal For propane gas the mani fold pressure must be between 9 7 and 10 3 inches water column 10 0 nominal Any major changes in flow must be made by changing the size of the burner orifices 6 CHECK THE GAS INPUT NATURAL GAS To measure the gas input using the gas meter proceed as follows a Turn off gas supply to all other appliances except the furnace b With the furnace operating time the smallest dial on the meter for one complete revolution If this is a 2 cubic foot dial divide the seconds by 2 if itis a 1 cubic foot dial use the seconds as is This gives the seconds pe
6. combustion can be inefficient incomplete or can possibly result in premature failure of the heat exchanger due to an excessive temperature rise The orifices in the high altitude kits have been selected as a result of testing with the American Gas Association They will provide appropriate derating at altitudes above 7500 feet for proper furnace performance The selection Derates See Exp 01 02 Sec V 7500 9500 ft 9500 11000 ft GUIA B070 7500 9500 ft 9500 11000 ft GUIA B090 7500 9500 ft 9500 11000 ft GUIA B115 7500 9500 ft 9500 11000 ft GUIAVB140 7500 9500 ft 9500 11000 ft GCIA B045 7500 9500 ft 9500 11000 ft GCIA B070 7500 9500 ft 9500 11000 ft 34 4 42 4 33 4 41 4 314 4 38 4 2744 34 4 2543 3043 34 4 42 4 33 4 41 4 GCIA B115 7500 9500 ft 9500 11000 ft GCIA B140 7500 9500 ft 9500 11000 ft 27 4 34 4 2543 3043 is based on non derated gas about 1000 BTU FT3 for natural gas and 2500 BTU Ft3 for propane gas If your gas supply has been derated for the altitude contact your gas supplier for orifice sizing Do not derate by adjusting the manifold pressure to a lower pressure reading than what is specified on the furnace nameplate With a lower density of air and a lower manifold pressure at the burner orifice the orifice will not aspirate the proper amount of air into the burner This can cause incomplete combustion of the gas flashback and or possible yellow
7. e stable soft and blue dust may cause orange tips but they must not be yellow They should extend directly outward fra the bumers without arlig floating or lifting off 9 Check the normal operating sequence of the ignition system to insure burners light properly 10 CHECK TEMPERATURE RISE NOTE The relationship between external static pres sure and temperature rise will be different than is shown in the installation instructions while the relationship between CFM and temperature rise will be approxi mately the same Temperature rise must still be within the limits shown on the unit nameplate Check the temperature rise through the unit by placing thermometers in supply and return air registers as close to the furnace as possible Thermometers must not be able to see the furnace heat exchanger or false readings could be obtained All registers must be open all duct dampers must be in their final fully or partially open position and the unit operated for 15 minutes before taking readings The temperature rise must be within the range speci fied on the rating plate NOTE Air temperature rise is the temperature differ ence between supply and return air If the correct temperature rise is not obtained it may be necessary to change the blower speed A higher blower speed will lower the temperature rise A slower blower speed will increase the temperature rise If itis necessary to adjust the blo
8. r cubic foot of gas being delivered to the furnace c INPUT GAS HTG VALUE x 3600 SEC PER CUBIC FOOT Example Natural gas with a heating value of 1000 BTU per cubic foot and 34 seconds per cubic foot as determined by Step 2 then Input 1000 x 3600 34 106 000 BTU per Hour NOTE BTU content of the gas should be obtained from the gas supplier 8600 is a conversion factor between seconds and hours This measured input must agree with the derates for your unit and elevation as indicated in Table 1 on page 2 Derating Example 1 GUIA115A40 at 8500 ft Sea level input 115000 BTU Hr From Table 1 Derate at 8500 ft 27 4 Since we are at the mid point of the evevation range we use the mid point of the derate 27 New Input 115000 x 1 27 83950 BTU Hr Derating Example 2 GUIA115A40 at 7500 ft Sea level input 115000 BTU Hr From Table 1 Derate at 7500 ft 27 4 Since we are at the lower end of the elevation range we use the lower derate 27 4 23 New Input 115000 x 1 23 88550 BTU Hr d Relight all other appliances turned off in step a Be sure all pilot burners are operating 7 CHECK THE GAS INPUT PROPANE GAS Verify the gas input rate by checking that the agoro priate orifices have been installed and the manifold pressure has been set as stated in these instructions 8 CHECK BURNER FLAMES Check burner flames through the view port in the burner box Flames should k
9. rform the following checks and adjustments 2 Tre positim of the ignitor relative to the huner is not effected by this conversion procedure but the ignitor should be visually inspected for any damage at this poirt 3 CHECK FOR LEAKS Leak check the orifice threads by using a soap solution Reinstall the burner box cover Aqwarnine To avoid the risk of fire or explosion do not use a flame to check for leaks sion kit If the unit is equipped with a White Rodgers 36E gas valve Figure 5a use Spring Kit 92 0659 Figure 5b If the unit is equipped with a Honeywell VR8205 gas valve Figure 6a use Spring Kit 393691 Figure 6b In each case change the regulator spring per instructions included with that particular regulator spring Discard whichever spring kits are not used Attach label shown in Figures 5B or 6B to gas valve indicating propane conversion MANIFOLD PRESSUR ADJUSTMENT Pr MANIFOLD 7 PRESSURE TAP 2 fe GAS VALVE FIGURE 6B HONEYWELL SPRING KIT CHECK GAS INPUT AND PRESSURES Check inlet gas pressure With the power and gas off connect a water manometer or adequate gauge to the inlet pressure tap of the gas valve With the power and gas on put the furnace into heating cycle andturn on all other gas consuming appliances For natural gas the inlet gas pressure should be between 5 0 and 10 0 inches of water For propane gas the inlet gas pressure should be between 11 0
10. tipping In addition to using smaller orifices to reduce the fuel input a different pressure switch must be used at altitudes above 7500 feet because of the reduced air density This is required regardless of the heat content of the fuel used HAC1PS HAC1PS HAC1PS HAC1PS HAC1PS HAC1PS HAC1PS HAC1PS HAC1PS 03 0 05 06 07 08 HAC1PS 09 10 GCIA B090 7500 9500 ft 31 4 9500 11000 ft 38 4 TABLE 1 PRESSURE SWITCH KITS CATEGORY I VENTING ONLY ll PRESSURE SWITCH INSTALLATION A caution The gas supply must be shut off prior to disconnecting the electrical power be fore proceeding with the conversion 1 Remove pressure switch Requires removing two mounting screws disconnecting rubber hose and dis connecting wiring See Fig 1 for typical location A caution To avoid the risk of fire property dam age or personal injury if disconnecting wires on the pressure switch make cer tain to reconnect the wires in the same location FIG 1 PRESSURE SWITCH 2 Install the pressure switch provided in this kit See Table 1 for the appropriate kit needed 3 Reconnect the hose Reconnect all wires Verify wiring on the wiring diagram located inside the blower compartment access panel 4 Proceed with orifice installation ORIFICE INSTALLATION Ay caution The gas supply must be shut off prior to disconnecting the electrical power be fore proceeding with the conversion L Remo
11. ve the gas manifold by removing the burner box front cover cutting the wire ties disconnecting the gas valve low voltage wires and removing the four manifold mounting screws See Figure 2 BURNER BOX r a r FRONT COVER r FIGURE 2 GAS MANIFOLD REMOVAL 2 Replace natural gas orifices Fig 3A amp 3B with the correct orifice kit depending on propane or natural gas usage and the altitude at the installation site Refer to Tables 2 or 3 for the appropriate kit required ORIFICES FIGURE 3A REPLACING GAS ORIFICES i FIGURE 3B ORIFICES KIT NO ALTITUDE ft ORIFICE HANGO6 7500 to 11000 Table 2 Natural Gas Orifice Kits This table assumes non derated natural gas about 1000 Btu ft3 If your gas supply has been derated for the altitude contact your gas supplier for orifice sizing KIT NO ALTITUDE ft ORIFICE HALP05 7500 to 11000 Table 3 Propane Gas Orifice Kits 4 Tighten orifices with a box end wrench Do not use a socket wrench as it could damage the orifices Do not overtighten Do not cross thread A caution To prevent premature heat exchanger failure follow the instructions below to remove all metal inserts from the heat exchanger tubes during propane conversions 5 If converting to propane gas remove metal screen inserts where present from the entrance of the heat exchanger tubes See Figure 4 and follow the a b c directions PARTITI
12. wer speed consult the furnace installation manual for details 11 For propane gas conversions attach conversion data plate with correct inout rating adjacent to the unit rating plate and post omversion cate certifi cate adjacent to the furnace COMPLETE THE INSTALLATION See the furnace installation manual for all installation details which were not covered in this booklet
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