HANG11-12 HALP10 HAPS27 IO MANUAL
Contents
1. Natural Gas Minimum 5 0 W C Maximum 10 0 W C Minimum 11 0 W C Maximum 13 0 W C If supply pressure differs from above make neces sary adjustments to pressure regulator gas piping size etc and or consult with local gas utility e Turn OFF gas to furnace at the manual shutoff valve and disconnect manometer Reinstall plug before turning on gas to furnace f Turn OFF any unnecessary gas appliances started in step c Check Manifold Pressure Only small variations in gas pressure should be made by adjusting the gas valve pressure regulator The manifold pressure must be measured with the burners operating To measure and adjust the manifold pres sure use the following procedure a Turn OFF gas to furnace at the manual gas shutoff valve external to the furnace b Connect a calibrated water manometer or appropri ate gas pressure gauge at the gas valve outlet pressure tap refer to gas valve figure in previous section c Turn ON the gas supply and operate the furnace d Measure gas manifold pressure with burners firing Adjust manifold pressure using the following table Manifold Gas Pressure Natural Gas The final manifold pressure must not vary more than 0 3 w c from the above specified pressures Any necessary major changes in gas flow rate should be made by changing the size of the burner orifice e To adjust the gas valve pressure regulator remove the regulator cap f T2. on or adjacent to the furnace Gas Valve On Off Selector Switch INLET gt gt OUTLET Outlet Manifold Inlet Pressure Tap Bie ita eee e l lde of Valve Side of Valve Under Cap Screw Figure 5 White Rodgers 36E22 Gas Valve Gas Valve gt a On Off C Control Knob gt OUTLET Pressure Regulator Outlet Manifold Adjustment Pressure Tap Inlet Pressure Tap Side of Valve Under Cap Screw Figure 6 White Rodgers Model 36E36 Pressure Regulator Adjustment Outlet Manifold Under Cap Screw Pressure Tap Honeywell 2 OUTLET INLET gt Inlet Pressure Tap Gas Valve On Off Control Knob Figure 7 Honeywell VR8205 Gas Valve Gas Valve On Off Control Lever Outlet Manifold In ON Position Pressure Tap Side of Valve INLET gt gt OUTLET Pressure Regulator Adjustment Under Cap Screw Inlet Pressure Tap Side of Valve Figure 8 Robertshaw Model 7222 V Operational Check The position of the ignitor relative to the burner is not affected by these conversion procedures 1 Visually inspect the ignitor for damage If there is damage replace the ignitor A WARNING To avoid the risk of fire or explosion do not use a flame to check for leaks 2 Leak test the orifice threads using a soap solution
3. If leaks are found repair before proceeding with opera tional check of furnace 3 Start the furnace using the procedures found in the furnace s installation instructions section Startup Pro cedures and Adjustments 4 Check Gas Supply Pressure The line pressure supplied to the gas valve must be within the range specified below The supply pressure can be measured at the gas valve inlet pressure tap or at a hose fitting installed in the gas piping drip leg The supply pressure must be measured with the burners operating To measure the gas supply pressure use the following procedure a Turn OFF gas to furnace at the manual gas shutoff valve external to the furnace b Connect a calibrated water manometer or appropri ate gas pressure gauge at either the gas valve inlet pressure tap or the gas piping drip leg NOTE At either location a hose fitting must be installed prior to making the hose connection Gas Line Gas Shutoff Valve Ne Gas Line To Furnace Open To Atmosphere Drip Leg Cap With Fitting I _ _ Manometer Hose Manometer Figure 9 Manometer c Turn ON the gas supply and operate the furnace and all other gas consuming appliances on the same gas supply line d Measure furnace gas supply pressure with burners firing Supply pressure must be within the range specified in the table below Inlet Gas Supply Pressure
4. pounds of oxygen in that air is reduced as the altitude increases lf this procedure is not followed and the fuel input is not reduced combustion can be inefficient incom plete or possibly result in premature failure of the heat exchanger due to an excessive temperature rise Rated Altitude without Change GUCA Up To GCCA 7000 Feet Table 1 Altitude Rating s HAPS27 Altitude pri 7001 9000 ft an acca 9001 11 000 ft 32 1 4 Table 2 Pressure Switch Kits 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 rated altitudes shown in Table 1 The selection is based on non derated gas about 1000 BTU Ft for natural gas and 2500 BTU Ft 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 setting other than what is specified on the furnace nameplate A lower air density in combination with a lower manifold pressure at the burner orifice will prohibit the orifice from aspirating the proper amount of air into the burner This can cause incomplete combustion of the gas flashback and or possible yellow tipping In addition to using smaller orifices to reduce the fuel input a different pressure switch must be used at altitudes above the rated altitudes shown
5. Amana Heating Air Conditionin A higher standard of comfort HANG11 amp 12 HALP10 and HAPS27 Kits High Altitude Conversion Installation Instructions A WARNING This conversion kit must be installed by a qualified agency in accordance with the manufacturer s instructions and all appli cable codes and requirements of the au thority having jurisdiction If the informa tion in these instructions is not followed exactly a fire explosion or production of carbon monoxide may result causing prop erty damage personal injury or loss of life The qualified service agency performing this work assumes responsibility for the proper conversion of this appliance with this kit KIT CONTENTS HANG11 12 High Altitude Natural Gas Installation instructions natural gas orifices wire ties HALP10 High Altitude Propane Gas Installation instruc tions propane orifices gas valve conversion kits with instructions conversion rating plate conversion date certificate wire ties and screen turbulator removal warn ing tag HAPS27 High Altitude Pressure Switch Installation instructions pressure switch IMPORTANT NOTE These kits are approved for use on Amana furnace models listed on the following page only These models are part of the family of 40 inch tall 90 percent condensing furnaces THE INSTALLATION AND SERVICING OF THIS EQUIPMENT SHOULD BE PERFORMED ONLY BY QUALIFIED EXPERIENCED TECHN
6. ICIANS THIS KIT IS NOT INTENDED FOR USE IN CANADA THE AMANA 90 FURNACES ARE CGA CERTIFIED TO 4500 FEET ONLY A RECOGNIZE THIS SYMBOL AS A SAFETY PRECAUTION ATTENTION INSTALLING PERSONNEL As a professional installer you have an obligation to know the product better than the customer This includes all safety precautions and related items Prior to actual installation thoroughly familiarize your self with this Instruction Manual Pay special attention to all safety warnings Often during installation or repair it is possible to place yourself in a position which is more hazardous than when the unit is in operation Remember it is your responsibility to install the prod uct safely and to know it well enough to be able to instruct a customer in its safe use Safety is a matter of common sense a matter of thinking before acting Most dealers have a list of specific good safety practices follow them The precautions listed in this Installation Manual should not supersede existing practices but should be consid ered as supplemental information Amana January 1999 Rev 1 Fayetteville TN 37334 10314615 I Description These kits are required when installing Amana Air Com mand 90 SSE furnaces above their maximum as shipped rated altitudes Table 1 Above rated altitude a derating of the appliance must be followed since the CFM moved by the induced draft blower remains almost constant while the
7. ic foot 34 sec ft Conversion Factor hours to seconds 3600 sec hr Input Htg value x 3600 seconds per cubic foot Input 1 000 BTU t x 3600 sec hr 34 sec ft Input 106 000 BTU hr This measured input must agree with the derates for your unit and altitude as indicated in Table 2 on page 2 Derating Example 1 GUCA115AX50 at 8000 ft Sea level input 115000 BTU Hr From Table 1 Derate at 8000 ft 15 344 Since we are at the mid point of the elevation range we use the mid point of the derate 15 3 New Input 115000 x 1 153 97 405 BTU Hr Derating Example 2 GUCA115AX50 at 7001 ft Sea level input 115000 BTU Hr From Table 1 Derate at 7001 ft 15 344 Since we are at the lower end of the elevation range we use the lower derate 15 3 4 11 3 New Input 115000 x 1 113 102 005 BTU Hr e Turn ON gas and relight all other appliances turned off in step 6a Be certain that all appliances are functioning properly and that all pilot burners are operating 7 Check The Gas Input Propane Gas Verify the gas input rate by checking that the appropri ate orifices have been installed and the manifold pressure has been set as stated in these instructions 8 Check Burner Flames With the burner compartment door in place check burner flames through the view port Flames should be stable soft and blue dust may cause orange tips but they must not be yellow They should extend direct
8. in Table 1 A high altitude pressure switch is required as a result of the reduction in air density This change is required regardless of the heat content of the fuel used ll HANG11 amp 12 HALP10 Orifice Installation A CAUTION To avoid the risk of fire property damage or personal injury shut off gas supply first then disconnect the electrical supply before proceeding with conversion 1 Remove the Gas Manifold Cut the wire ties securing the wire harness to the manifold Disconnect low voltage wires from gas valve and remove the four mounting screws See Figure 1 Burner Burner Bracket Figure1 Gas Manifold Removal 2 Replace Gas Orifice a Remove the standard altitude natural gas orifices Figure 2 amp 3 and replace with orifices from the appropriate kit Kit usage depends on an installation s gas usage natural or propane and altitude Refer to Table 3 or 4 for the appropriate kit requirements A 7 N Orifices Len Figure 2 Replacing Gas Orifices Figure 3 Orifices Kit AIRES Non A Orifice GUCA coca HANG11 7001 9000 nae GUCA HANG12 1 11 GCCA cad 8 NOTE Units Installed in Canada are certified to 4500 feet only therefore these kits are not applicable in Canada Table 3 Natural Gas Orifice Kits This table assumes non derated natural gas about 1000 BTU Ft If your gas supply has been derated for the altitude contact your gas
9. ing 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 AX CAUTION To prevent unsatisfactory furnace operation the proper gas conversion kit must be used for each valve Use the White Rodgers spring kit only with the White Rodgers gas valve Honeywell spring kit only with the Honeywell gas valve and Robertshaw spring kit only with the Robertshaw 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 Replace the gas valve regulator spring with one of the new springs included in this propane gas conversion kit If the unit is equipped with a White Rodgers 36E gas valve Figures 5 amp 6 use Spring Kit 92 0659 If the unit is equipped with a Honeywell VR8205 gas valve Figure 7 use Spring Kit 393691 If the unit is equipped with a Robertshaw 7222 gas valve Figure 8 use Spring Kit 54300 In each case change the regulator spring per instruc tions included with that particular regulator spring Discard unused spring kits 2 Attach the label found in the spring kit to the gas valve indicating propane conversion 3 Attach conversion data plate with correct input rating adjacent to the unit rating plate 4 Post conversion date certificate
10. ly outward from the burners without curling floating or lifting off 9 Check the normal operating sequence of the ignition system to insure burners light properly 10 Check Temperature Rise Temperature rise must be within the range specified on the unit rating plate An incorrect temperature rise may result in condensing in or overheating of the heat exchanger An air flow and temperature rise table is provided in the specification sheet Determine and adjust temperature rise as follows NOTE At higher altitudes the relationship between external static pressure and temperature rise will be different than is shown in the installation instructions while the relationship between CFM and temperature rise will be approximately the same Temperature rise must still be within the limits shown on the unit name plate a Operate furnace with burners firing for approxi mately ten minutes Ensure all registers are open and all duct dampers are in their final fully or partially open position b Place thermometers in the return and supply ducts as close to the furnace as possible Thermometers must not be influenced by radiant heat by being able to see the heat exchanger HEAT EXCHANGER RADIATION LINE OF SIGHT SUPPLY AIR i TSUPPLY RISE SUPPLY TRETURN i TRETURN RETURN AIR Figure 10 Temperature Rise Measurement c Subtract the return air temperature from the supply air tempera
11. supplier for orifice sizing NOTE Units Installed in Canada are certified to 4500 feet only therefore these kits are not applicable in Canada Table 4 Propane Gas Orifice Kits b 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 c Reinstall the gas manifold to burner bracket assem bly using screws removed in step 1 Make certain the orifices are inserted in each burner and that each burner remains properly seated in the burner bracket d Connect low voltage gas valve wires to gas valve Refer to wiring diagram for proper connection e Wire tie wiring harness to manifold Make certain wires do not interfere with gas flow from orifices or through burners or contact any hot surfaces NOTE If converting to propane gas see PROPANE GAS CONVERSION section for additional instructions Ill HAPS27 Pressure Switch Installation A WARNING To avoid death or personal injury due to electrical shock disconnect the electrical supply to the furnace before installing this kit or performing any service 1 Shut off gas and disconnect power supply to furnace 2 Locate the induced draft blower pressure switch Yellow and Orange Electrical Connections p Mounting Bracket Screw Induced Draft Blower Pressure Swi
12. tch Mounting Screws Induced Draft Blower Pressure Switch Pressure Switch Hose Induced Draft Blower Figure 4a Induced Draft Blower Pressure Switch Location GUCA Mounting Bracket Screws Underneath Blower Deck Induced Draft Blower Induced Draft Blower Pressure Switch Mounting Screws Induced Draft Blower Pressure Switch Yellow and Orange Electrical Connections Pressure Switch Hose Figure 4b Induced Draft Blower Pressure Switch Location GCCA Ad CAUTION To avoid personal injury or property damage due to fire make certain all wires disconnected from the pressure switch during this procedure are properly reconnected 3 Disconnect the pressure switch hose from the pres sure switch 4 Disconnect the yellow and orange wires from pressure switch 5 Remove pressure switch Upflow GUCA models Figure 4a Remove pressure switch mounting bracket screw se curing pressure switch and mounting bracket to parti tion panel Counterflow GCCA models Figure 4b Remove mounting bracket screws securing pressure switch and moun
13. ting bracket to blower deck 6 Remove screws from mounting bracket and transfer the bracket to the HAPS27 pressure switch Be sure to maintain the same orientation as on the standard altitude switch 7 Install the HAPS27 pressure switch using screw s removed in step 5 8 Connect the yellow and orange wires to the HAPS 27 pressure switch 9 Reconnect the pressure switch hose to new switch 10 Verify proper furnace operation IV HALP10 Propane Gas Conversion A WARNING 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 aboutinstalling a warning device that would alert you to a gas leak Propane gas is heavier than air and any leaking gas can settle in any low areas or confined spaces Propane gas odorant may fade making the gas undetectable except with a warning device An undetected gas leak would create a danger of explosion or fire If you suspect the presence of gas follow the instructions on the cover of the furnace installation manual Failure to do so could result in SERIOUS PERSONAL INJURY OR DEATH AQ WARNING 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 warn
14. ture to determine the air temperature rise Allow adequate time for thermometer readings to stabilize d Adjust temperature rise by adjusting the circulator blower speed Increase blower speed to reduce temperature rise Decrease blower speed to in crease temperature rise If it is necessary to adjust the blower speed consult the furnace installation manual for details VI Complete The Installation Refer to the furnace installation manual for all installation details which were not covered in this manual
15. urnthe adjustment screw clockwise to increase the pressure or counterclockwise to decrease the pres sure g Securely replace the regulator cap h Turn OFF gas to furnace at the manual shutoff valve and disconnect manometer i Reinstall gas valve outlet pressure tap plug before turning on gas to furnace Check Gas Input Rate Natural Gas Only The gas input rate to the furnace must never be greater than that specified on the unit rating plate To measure the gas input using the gas meter proceed as follows a Turn OFF the gas supply to all other gas burning appliances except the furnace b While the furnace is operating time and record one complete revolution of the smallest gas meter dial c Calculate the number of seconds per cubic foot sec ft of gas being delivered to the furnace Ifthe dial is a one cubic foot dial divide the number of seconds recorded in step 2 by one Ifthe dialis atwo cubic foot dial divide the number of seconds re corded in step 2 by two d Calculate the furnace input in BTUs per hour BTU hr Input equals the sum of the installation s gas heating value and a conversion factor hours to seconds divided by the number of seconds per cubic foot The measured input must not be greater than the input indicated on the unit rating plate INPUT CALCULATION EXAMPLE Installation s gas heating HTG value 1 000 BTU ft Obtained from gas supplier Installation s seconds per cub
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