Renzor OPT-GC Gas Conversion Parts Instruction Manual

Renzor OPT-GC Gas Conversion Parts

Safety Instructions

• A caution statement describes a potentially hazardous situation that, if not avoided, can result in minor or moderate personal injury and/or property damage.
• A note provides important information that should not be ignored.
• Gas conversion should be made only by a qualified service technician.
• Improper conversion will result in severe personal injury or death.
• The Manufacturer will not accept responsibility or liability as a result of improper gas conversion.
• Improper selection or servicing could result in death, severe personal injury, and/or property damage.
• This instruction sheet includes parts and instructions for several models.
• It applies only to the models listed on the front page and requires the selection of individual parts.
• If your model is listed, contact your distributor to obtain a kit designed specifically for your application.
• If your heater model is not listed in either place, conversion parts are not available.

Model Number

The identifying model number can be found on the heater rating plate. The rating plate identifies only original equipment, so also check the actual gas valve label and look for any gas or ignition conversion labels. When converting fuels, you must have the complete heater model number. Refer to Table 1 to decode a heater model number.

Selecting Parts

If the unit being converted has multiple furnace sections, order all parts for each furnace. Required conversion parts for models without conversion kits must be selected individually. The following parts are required for gas conversion:

• Select Spring Regulator Kit or Replacement Valve section)
• Select Natural Gas or Propane Gas Pilot Orifice section)
• Select the Main Burner Orifices section.
• Burner air shutters (required only for conversion from natural gas to propane)
• Conversion Disk or Conversion Label Selection section)
• Ignition controller (required only for conversion from natural gas to propane with spark pilot). Select Ignition Controller (for Natural Gas to Propane Conversion with Spark Pilot) section)
• Select the Carryover Parts section. Select conversion parts by the following steps.

Select Spring Regulator Kit or Replacement Valve

Select Ignition Controller (for Natural Gas to Propane Conversion with Spark Pilot)

When converting indoor units with a spark pilot (indoor and outdoor in Canada) to propane, the ignition controller must have a 100% lockout. Refer to the flowchart shown in Figure 1 for ignition controller selection.

Select Carryover Parts

Carryover Lighter Tube System Determination

• Burner Rack Without Carryover Lighter Tube
• Burner Rack with Lighter Tube Carryover System Without Regulator (Used with Natural Gas)
• Burner Rack with Lighter Tube Carryover System with Regulator (Used with Propane Gas)

Carryover Lighter Tube System for Propane to Natural Gas Conversion

For propane to natural gas conversions, order the carryover lighter tube orifice listed in Table 10 (if required) plus the following:

• One (1) elbow, brass (PN 93388)
• One (1) tube, carryover, 8-3/4 (PN 93389)
• One (1) fitting, compression (PN 9664)

Models (H)RP, (H)CRP, (H)RPB, (H)CRPB; Models (H)RPV, (H)CRPV Series 6, 7, and 8; Models SC, SCA, SCB, SCE Series 6; Models (H)X, (H)XE, PAK Series 8; and Model PGBL do not require a carryover orifice change when converting from either propane to natural gas or natural gas to propane. When converting to natural gas, remove the regulated carryover lighter tube (see Figure 2) and install the natural gas carryover tube using the original (propane) carryover orifice.

Select Carryover Lighter Tube System for Natural Gas to Propane Conversion

For natural gas to propane conversions, order the carryover lighter tube orifice system parts listed in Table 11 (if required) plus one (1) regulated carryover assembly (PN 100712) as shown in Figure 3. The regulator is factory-set at 1 inch of pressure at the outlet. DO NOT CHANGE PRESSURE SETTING. For units with multiple furnaces, order parts for each furnace.

(H)SC, SCA, SCB, SCE series 6; (H)X, (H)XE, PAK series 8; and PGBL do not have a lighter tube carryover system on a natural gas burner. When converting to propane, remove the burner and remove the factory-installed flash carryover from the orifice end of the burner rack—do not remove the flash carryover from the other end of the burner rack. Order the drip shield and carryover lighter tube listed by PN and install as shown in Figure 4.

• (H)RP, (H)CRP, (H)RPB, (H)CRPB, (H)RPV, (H)CRPV series 6, 7, and 8 do not require a carryover orifice change when converting from either propane to natural gas or natural gas to propane. When converting to propane, they do require the addition of the regulated carryover assembly (PN 100712) using the original (natural) carryover orifice.
• LG = length in inches.

Installation of Gas Conversion Parts

1. SC series burner racks include a burner rack skirt that is used only on separated-combustion models.)
   • Remove the side panel from the unit.
2. Replace burner orifices.
   • • Remove two screws that secure the bottom of the burner rack assembly.
3. Replace the pilot orifice.
   • Remove screws and lift out the pilot burner.
4. Install valve regulator spring kit.
   • Follow the valve manufacturer’s installation instructions that are included with the spring kit.

• Remove 1/4-inch sheet metal screws in manifold mounting angles and remove the manifold assembly.

• Remove 1/4-inch sheet metal manifold bracket screws and remove the manifold assembly.
• If orifice change is required, insert the replacement orifice.
• Reverse the above procedures to reassemble the heater.
  

• Turn ON electricity and gas. Relight the heater.
  

Flame and Pressure Adjustments

When installation of gas conversion parts is complete, adjust the pilot lame and the manifold pressure as follows.

Adjust Pilot Flame

Refer to Figure 11, which shows the desired pilot flame height, and adjust the pilot flame as follows.

1. Loosen and remove the pilot adjustment cover screw on the valve.
2. Turn the inner adjustment screw counterclockwise to increase flame or clockwise to decrease flame.
3. Install and tighten the pilot adjustment cover screw on the valve.

Adjust Manifold Gas Pressure

For Natural Gas

High fire manifold pressure is regulated by the combination valve to 3.5 IN WC. Inlet pressure to
The valve must be a minimum of 5 IN WC or as noted on the Renzor OPT-GC Gas Conversion Parts rating plate and a maximum of 14 IN WC.

For Propane

The regulator in the valve must be adjusted to provide a manifold pressure of 10 IN WC. Inlet pressure to the valve must be a minimum of 11 IN WC and a maximum of 14 IN WC. Measure and adjust (if required) the manifold gas pressure as follows:

• Position the manual valve (on the combination valve) to prevent flow to the main burner.
• Connect the manometer to the 1/8-inch pipe outlet pressure tap in the valve.
• Open the valve and operate the heater to measure the manifold gas pressure.
• If the manometer indicates that the manifold gas pressure needs adjustment, set the correct pressure by turning the regulator screw on the valve Renzor OPT-GC Gas Conversion Parts IN (clockwise) to increase pressure or OUT (counterclockwise) to decrease pressure.
• Disconnect the manometer from the 1/8-inch pipe Renzor OPT-GC Gas Conversion Parts outlet pressure tap in the valve.

Gas Conversion of Direct-Fired Furnaces

Perform gas conversion of direct-fired furnaces as follows:

• Shut OFF the gas at the main manual shut-off. Turn the electricity off at the disconnect switch.
• Open the burner section door panel.
• For ADF/ADFH models, replace the pilot gas regulator. Refer to Figure 12 to select a replacement pilot gas regulator.
• For the ADF/ADFH model that does not have electronic Renzor OPT-GC Gas Conversion Parts modulation gas controls, follow the valve manufacturer’s instructions to install the spring regulator kit or to install the replacement valve.
• Locate the pressure regulator and remove the cap (see Figure 13) and the adjustment screw from the pressure regulator. The regulator spring is now visible.

• Remove the regulator spring.
• Refer to Table 12 to select the replacement regulator Renzor OPT-GC Gas Conversion Parts spring.
• Install the replacement regulator spring and replace the adjustment screw.
• Measure gas pressure at the burner and adjust the pressure to meet application requirements.
• Replace the cap on the pressure regulator.
• Turn ON the electricity at the disconnect switch.
• Turn ON the gas at the main manual shutoff.
• Replace the burner section door panel. Unit is now Renzor OPT-GC Gas Conversion Parts operational from the system switch on the remote console.

Startup Checklist

Check for safe and proper operation of the heater as follows:

• Operate the heater for at least one cycle
• Cautiously observe the main burners for complete flame carryover.
• Flame must be present on the full length of each burner.
• Adjust air shutters (if used) after the heater has been in operation for 15 minutes.
• Turn adjustment screws to close air shutters no more than necessary to eliminate any problem condition.
• Observe flame for yellow tipping. A limited Gas Conversion and Ignition Conversion Kitsmount Renzor OPT-GC Gas Conversion Parts of yellow tipping is permissible for propane.
• Complete information is required on the Renzor OPT-GC Gas Conversion Parts conversion label. Attach the disk to the heater near the gas valve.

Gas Conversion and Ignition Conversion Kits

Ignition conversion kits are NOT gas conversion kits.

Limited Warranty

Reznor LLC warrants to the original owner-user that this product will be free from defects in material and workmanship. This warranty is limited to twelve (12) months from the date of original installation, whether or not actual use begins on that date, or eighteen (18) months from the date of shipment, whichever occurs first.

Manufacturer Replacement Parts Limited Warranty

Reznor LLC warrants replacement parts for thirty (30) days after installation or thirteen (13) months from the date of shipment, whichever occurs first.

Customer Support

• Website: www.reznorhvac.com
• Ph: 800-695-1901