Original message
| siestavista
 |  "overfireing furnace"
, posted Wed 8 Oct 13:06  
an old sears furnace has been retrofited with a new gas valve and standing pilot where an old spark ignightor existed. it has a 42 oriface. It has not been deregulated for altitude. at 4,600'and a specific gravity of 1000 btu for the natural gas 80% of 75,000btu input rating= 60,000. if you look on the chart it will read an oriface size of (i'm guessing here) 38. am i in the ball park?
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Replies:
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| siestavista
| "Re(1):overfireing furnace" , posted Fri 10 Oct 20:35
HIGH ALTITUDE
INSTALLATION INSTRUCTIONS
For HA02 Conversion Kit
Nat. & L.P. Gases
IMPORTANT NOTICE
This conversion kit is to convert the gas furnace for higher altitudes. These instructions are intended
for the use of qualified individuals who are trained and experienced in the installation and conversion
of this type of equipment. Personnel performing this task are required in some states to be licensed.
Under no circumstances should this conversion, or equipment installation be performed by personnel
who are not qualified. Failure to observe this warning may result in equipment damage, fire, or life
threatening danger. Refer to the equipment installation manual, the National Fuel Gas Code (ANSI
Z223.1), or in Canada (CAN/CGA1-2.17-M91), and local codes.
PARTS LIST
Using the following parts list, ensure that all parts included in this list are present and in an undamaged condition.
WARNING
IF ANY DOUBT EXISTS ABOUT THE CONDITION OF ANY COMPONENT WITHIN THIS KIT, DO NOT USE THIS KIT
AND CONTACT YOUR SUPPLIER FOR A NEW KIT.
DESCRIPTION PART NUMBER QUANTITY
Installation Instructions IO-552 1
Conversion Label B14933-63 1
Burner Orifices B25899-01 thru -10 6 ea./pack
PARTS LIST
TOOLS REQUIRED FOR INSTALLATION
(2) Pipe Wrenches. These wrenches shall be suitably
sized to handle the supply piping and its ground joint
union.
(1) 7/16 open or closed wrench. Do not use an
adjustable wrench when removing or installing burner
orifices.
(1) 5/16 nut driver.
(1) Flat blade screw driver.
All information contained herein is subject to change without notice.
Goodman Manufacturing Company, L.P.
I0-552A 2550 North Loop West, Suite 400, Houston, TX 77092 08/04
www.goodmanmfg.com
© 2004 Goodman Manufacturing Company, L.P.
(1) 3/16 Allen wrench. The Allen wrench is required to
remove gas valve inlet and outlet plugs.
(2) Water Column manometers. Manometers are to be
capable of reading a range between 0 and 20 inches
with 1" increments. Pipe thread compound. Pipe
thread compound used must be listed as appropriate
material for LP gas. Soap solution and application
brush.
IO-552A 2 08/04
INSTALLATION
WARNING
NEVER USE AN OPEN FLAME WHEN CHECKING
FOR GAS LEAKS. USING AN OPEN FLAME COULD
RESULT IN FIRE, CAUSING PROPERTY DAMAGE,
PERSONAL INJURY OR DEATH.
WARNING
TURN OFF ELECTRICAL POWER AND GAS SUPPLY
TO THE APPLIANCE.
1. Prior to performing this conversion, refer to the Installation
& Operation Manual supplied with the unit, the National
Fuel Gas Code (ANSI Z223.1) or in Canada CAN/CGA1-
2.17-M91), and local codes to ensure that this appliance
is installed correctly and in compliance with these codes/
manuals.
2. Set the room thermostat to its lowest possible setting.
3. Remove the furnace control access door. See figure 1 for
the location of these components.
4. Loosen the gas supply ground union, and remove the
gas valve supply line. Use one pipe wrench as a back-up
to prevent damage/rotation of any controls.
5. Remove the (4) sheet metal screws which fasten the gas
manifold to the burner box. See figure 1. for component
location. On PGB series take care not to break the Hot
Surface Ignitor on the pilot assembly.
6. Using the 7/16 wrench, remove the existing natural gas
orifices from the burner manifold. Discard the natural gas
orifices.
7. Install the orifices supplied with this kit into the gas
manifold. Look at sizes stamped on orifice face to insure
that all the same are installed. Tighten these orifices
adequately to prevent gas leakage. Refer to table 1 for the
correct burner orifices.
8. Using the 3/16 Allen wrench, remove both the gas valve
inlet and outlet pressure plugs. Retain these plugs.
9. Install a barb hose connector into both the gas valve inlet
and outlet pressure ports. Note: The gas valve pressure
ports are threaded to accept a 1/8 NPT fitting. Do not use
a barbed hose connector that is threaded for anything other
than 1/8 NPT.
10. Reinstall gas manifold assembly into furnace.
11. Connect both the inlet and outlet gas valve barb fittings
(installed in step 9) to (2) separate manometers. See figure
2.
12. Apply a liberal quantity of pipe thread compound to all
threaded portions of the gas supply piping. Pipe compound
must be resistant to the effects of LP gas.
13. Install the gas supply piping and its ground union joint
using a pipe wrench. Use a second pipe wrench as a back
up.
WARNING
DO NOT USE AN OPEN FLAME TO CHECK THE GAS
SUPPLY LINE, GAS VALVE INLET AND OUTLET
PRESSURE AREAS.
14. Turn on the gas supply to the furnace. Using a soap and
water solution, check the gas supply line, gas valve inlet
and outlet pressure areas. Repair any gas leaks detected.
15. Turn on the electric supply to the furnace.
16. Adjust the room thermostat to obtain continuous
burner operation.
17. After the burner is in operation for 15 minutes, check
and adjust, if needed , the supply and manifold pressure.
See figure 2.
18. Adjust the burner air shutters to obtain a burner flame
consistent with the flame shown in the furnace Installation
& Operating Instructions.
19. Turn off the gas and electrical supply to the furnace.
20. Apply the conversion label adjacent to the rating plate.
21. Remove the barb fittings and manometers installed on
the gas valve. Install the gas valve inlet and outlet pressure
plugs.
22. Turn on the gas and electrical supply. Adjust the room
thermostat to ensure continuous burner operation.
WARNING
DO NOT USE AN OPEN FLAME TO CHECK THE GAS
SUPPLY LINE, GAS VALVE INLET AND OUTLET
PRESSURE AREAS, AND THREADED PORTIONS OF
THE BURNER ORIFICES FOR LEAKS.
23. Using a soap solution check the gas supply, gas valve
inlet and outlet pressure areas, and threaded portions of
the burner orifices for leaks. Repair any gas leaks detected.
24. Observe at least three ignition cycles to ensure smooth
and quiet ignition.
25. Install the control access panel.
IO-552A 3 08/04
BURNER MANIFOLD
BURNER BOX
GAS VALVE
ACCESS DOOR
FIGURE 1
Note: Typical Up-flow Furnace. Actual Models May Differ.
GAS FLOW
INLET (SUPPLY)
PRESSURE
MANOMETER
(FIELD SUPPLIED)
NOTE! SUPPLY
PRESSURE IS TO BE
BETWEEN 5.0 & 7.0
NAT AND 11.0 & 14.0
L.P. INCHES WITH THE
FURNACE OPERATING.
INLET (SUPPLY)
PRESSURE
HOSE FITTING
(FIELD SUPPLIED)
OUTLET (MANIFOLD)
PRESSURE
HOSE FITTING
(FIELD SUPPLIED)
OUTLET (MANIFOLD)
PRESSURE
MANOMETER
(FIELD SUPPLIED)
NOTE! MANIFOLD
PRESSURE IS TO BE
BETWEEN 3.2 & 3.7
NAT AND 10.0 & 11.0
L.P. INCHES.
FIGURE 2
IO-552A 4 08/04
Table 1, 2 and 3 are based upon the furnace input being reduced for altitudes above sea level. U.S. 4% per 1000 feet.
Canada 10% derate for 2000-4500 feet. To determine input/burner, locate input rate on plate and divide by number of
burners. If specific input/burner is not listed, use the values of the next lower table (i.e. If input/burner is 24,500, use
the values in Table1, if input/burner is 21, 800, use Table 3, etc.).
INPUT/BURNER
2000 3000 4000 4500 5000 6000 7000 8000
U.S. BURNER ORIFICE 44/55 44/55 45/56 45/56 46/57 47/58 47/58
CANADA BURNER ORIFICE 44/55 47/57
INPUT/BURNER
2000 3000 4000 4500 5000 6000 7000 8000
U.S. BURNER ORIFICE 43/55 53/55 44/56 44/56 44/56 45/57 45/57
CANADA BURNER ORIFICE 43/55 46/57
INPUT/BURNER
2000 3000 4000 4500 5000 6000 7000 8000
U.S. BURNER ORIFICE 45/55 47/55 47/56 47/56 48/57 48/58 49/58
CANADA BURNER ORIFICE 45/55 48/57
20,000 BTUH NAT/20,OOO BTUH/L.P.
ELEVATION ABOVE SEA-LEVEL (FEET)
TABLE 1
TABLE 2
TABLE 3
22,500 BTUH NAT/20,OOO BTUH/L.P.
ELEVATION ABOVE SEA-LEVEL (FEET)
25,000 BTUH NAT/20,OOO BTUH/L.P.
ELEVATION ABOVE SEA-LEVEL (FEET)
Quality Makes the Difference!
All of our systems are designed and manufactured with the same high quality standards regardless
of size or efficiency. We have designed these units to significantly reduce the most frequent causes
of product failure. They are simple to service and forgiving to operate. We use quality materials and
components. Finally, every unit is run tested before it leaves the factory. Thats why we know. . .
Theres No Better Quality.
Visit our web site at www.goodmanmfg.com for information on:
Goodman products
Warranties
Customer Services
Parts
Contractor Programs and Training
Financing Options
© 2004 Goodman Manufacturing Company, L.P.
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