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.

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.

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.

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.

Important 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 of the correct size. This procedure assures that the orifices provided are the correct size.

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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.

DShut off gas supply to furnace at manual shut--off valve be- fore starting installation.

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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.

DDisconnect electric power supply to the furnace before starting installation.

DCheck for gas leaks after installation of kit and before at- tempting to start furnace.

DLocate the Natural Gas Conversion Label next to the fur- nace rating plate.

DFill out and attach the Field Conversion Label to the front ex- terior of the furnace.

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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 in 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

DRefer to the furnace rating plate for the approved gas input rating.

DGas input to burners MUST NOT exceed the rated input shown on rating plate.

DDo 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.

Installation

!

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.

Turn OFF gas supply at manual gas valve before turning OFF electric power supply and starting installation.

Turn OFF electric power supply at disconnect switch or service panel before starting installation.

Disassembly

Refer to Figure 1 and the following steps.

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.

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.

2.Tighten the orifices so they are 13/16??? from the face of the 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.

Measure 13/16??? 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)

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.

Figure 6 Burner Pilot Assembly

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.

Figure 7

Inlet Pressure

Tap (Hidden)

INLET

Typical Gas Valve Honeywell

SV9500

Pilot Adjustment

OUTLET

Inlet Pressure

Tap (Hidden)

Pilot

Adjustment

4.Install the pressure regulator adjusting screw. This will set the manifold pressure close to required setting for normal operation.

5.Replace the regulator cap screw.

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.

DManifold Assembly -- Be sure to engage the main burner orifices in the proper openings in the burners.

DTesting 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

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.

3.Close manual gas line valve to unit, remove manometer and replace inlet pressure tap plug.

Gas Valve Adjustment

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).

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.

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???.

7.Turn gas valve to OFF. Remove the pressure gauge and re- place the pressure tap plug and pressure regulator cap screw.

8.With gas valve on, observe furnace through two or more complete cycles to be sure all controls are operating.

462 06 1211 00 3/17/06

!

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.

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:

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).

Pilot Burner Flame Check (All models except PGF3, PGX3, and PDX3)

Adjust flames so they surround 3/8??? (9 mm) to 1/2??? (13 mm) of the sensor tip (See Figure 11).

1.Remove the cap from the pilot adjusting screw (See Fig- ures 7 & 8).

2.Turn pilot adjusting screw counterclockwise to increase, clockwise to decrease.

3.Replace the cap on the pilot adjusting screw.

Figure 11 Pilot Burner (HSP)

Main Burner Flame Check

Check for the following:

DStable and blue flames (See Figure 12). Dust may cause orange tips or wisps of yellow, but flames MUST NOT have solid, yellow tips.

D Flames extending directly from burner into heat exchanger. D Flames DO NOT touch sides of heat exchanger

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