Honeywell Wok PGF3 User Manual

Installation Instructions For Natural Gas Conversion  
(Kit Part No. 1173865)  
This kit is designed for conversion to Natural Gas.  
Natural Gas Orifice Kits and Sizes  
Elevation Above Sea Level  
Table 1  
0 to 2000 ft  
2001 to 4000 ft 4001 to 5000 ft  
5001 to 6000 ft 6001 to 7000 ft 7001 to 8000 ft 8001 to 9000 ft 9001 to 10000 ft  
Orifice Drill #  
Orifice Drill #  
Orifice Drill #  
Orifice Drill #  
Orifice Drill #  
Orifice Drill #  
Orifice Drill #  
Model Number  
PGAA, PGMD (All Sizes)  
Orifice Drill #  
Kit Number  
1173863  
(Field-Supplied) (Field-Supplied) (Field-Supplied) (Field-Supplied) (Field-Supplied) (Field-Supplied) (Field-Supplied)  
44  
44  
44  
44  
44  
44  
41  
42  
42  
44  
44  
44  
41  
42  
42  
45  
45  
45  
45  
45  
45  
43  
43  
43  
45  
45  
45  
43  
43  
43  
46  
46  
46  
46  
46  
46  
43  
43  
43  
46  
46  
46  
43  
43  
43  
47  
47  
47  
47  
47  
47  
43  
44  
44  
47  
47  
47  
43  
44  
44  
47  
47  
47  
47  
47  
47  
44  
44  
44  
47  
47  
47  
44  
44  
44  
48  
48  
48  
48  
48  
48  
44  
45  
45  
48  
48  
48  
44  
45  
45  
48  
48  
48  
48  
48  
48  
45  
46  
46  
48  
48  
48  
45  
46  
46  
49  
49  
49  
49  
49  
49  
46  
47  
47  
49  
49  
49  
46  
47  
47  
PGAD, PGME (All Sizes)  
1173863  
1173863  
1173863  
1173863  
1173863  
1173865  
1173865  
1173865  
1173863  
1173863  
1173863  
1173865  
1173865  
1173865  
PGX3, PDX3 (All Sizes)  
PGC***K040F, GPCM**K040  
PGC***K060F, GPCM**K060  
PGC***K080F, GPCM**K080  
PGC***K100F, GPCM**K100  
PGC***K120F, GPCM**K120  
PGC***K140F, GPCM**K140  
PGF***K040F, GPFM**K040  
PGF***K060F, GPFM**K060  
PGF***K080F, GPFM**K080  
PGF***K100F, GPFM**K100  
PGF***K120F, GPFM**K120  
PGF***K140F, GPFM**K140  
PGS***K040F, GPSM**K040  
PGS***K060F, GPSM**K060  
PGS***K080F, GPSM**K080  
PGS***K100F, GPSM**K100  
PGS***K120F, GPSM**K120  
PGS***K140F, GPSM**K140  
PGF3**040  
44  
44  
44  
41  
42  
42  
44  
44  
44  
41  
42  
42  
1173863  
1173863  
1173863  
1173865  
1173865  
1173865  
1173863  
1173863  
1173863  
1173865  
1173865  
1173865  
45  
45  
45  
43  
43  
43  
45  
45  
45  
43  
43  
43  
46  
46  
46  
43  
43  
43  
46  
46  
46  
43  
43  
43  
47  
47  
47  
43  
44  
44  
47  
47  
47  
43  
44  
44  
47  
47  
47  
44  
44  
44  
47  
47  
47  
44  
44  
44  
48  
48  
48  
44  
45  
45  
48  
48  
48  
44  
45  
45  
48  
48  
48  
45  
46  
46  
48  
48  
48  
45  
46  
46  
49  
49  
49  
46  
47  
47  
49  
49  
49  
46  
47  
47  
PGF3**060  
PGF3**080  
PGF3**100  
PGF3**120  
PGF3**140  
Note: "**" or "***" may be any combination of numbers and/or letters in the model number.  
Note: The orifice sizes in the chart above derate the input rate at 4% per 1000 feet above sea level for altitudes exceeding 2000 feet above sea level.  
Natural gas data is based on .60 specific gravity, a heating value of 1030 Btu/cubic foot, and 3.5 "W.C. manifold pressure.  
For fuels with different specific gravity and/or different heating values, consult the National Fuel Gas Code ANSI Z223.1 - 2002/NFPA 54-2002 or  
National Standard of Canada, Natural Gas and Propane Installation Code CSA B149.1-00.  
Note: If converting from LP gas to Natural gas at altitudes exceeding 2000 feet above sea level, conversion kit (Part #330732-401) is required for proper conversion. For all models, except PGX3, PDX3, and PGF3, a .018 pilot  
orifice (Part # 5032110) is also required.  
Parts List, Kit # 1173865  
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.  
Description  
Part #  
Qty  
7
Burner Orifice #41  
1096942  
1011351  
Burner Orifice #42  
7
Pilot Orifice (0.018)  
Honeywell Conv. Kit #396222  
Label, Natural Gas Conversion  
Label, Field Conversion  
Instructions  
503211  
1172952  
1
1
1173866  
1
1009678  
1
462 06 1211 00  
1
SAFETY REQUIREMENTS  
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.  
!
Recognize safety information. This is the safety--alert symbol  
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.  
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.  
462 06 1211 00  
3/17/06  
-- 1 --  
 
Disassembly  
Figure 2  
Installing NOx Baffles  
Refer to Figure 1 and the following steps.  
Disassembly  
Figure 1  
or  
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.  
Changing Orifices  
Figure 3  
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.  
3
2. Tighten the orifices so they are 1 / from the face of the  
16  
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.  
462 06 1211 00  
3/17/06  
-- 3 --  
 
Figure 4  
Figure 6  
Burner Pilot Assembly  
Manifold/Orifice Measurement  
3
Measure 1 /16from 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)  
Gas Valve Conversion (Required for Converting  
from Propane Gas to Natural Gas)  
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.  
Conversion of Honeywell VR8200, SV9500, SV9501 and  
VR8204M Gas Valves using Natural Gas Conversion Kit #  
396222.  
Changing Pilot Orifice  
Figure 5  
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.  
Typical Gas Valve Honeywell  
SV9500  
Figure 7  
Pilot  
Orifice  
Inlet Pressure  
Tap (Hidden)  
Wiring  
Terminals  
ON  
OFF  
Honeywell  
WARNING  
Explosion Hazard.  
Serious injory or death  
can result.  
IGNITER  
Read instructions before  
operating valve.  
Never  
operate valve  
use tools to  
disassemble valve. call  
a
qualified service technician  
.
if the appliance does not  
Pilot  
Outlet  
Do not  
function properly.  
CONTROL  
INLET  
OUTLET  
Pilot Adjustment  
Outlet Pressure Tap  
25-50-06  
Connect manometer here to  
check outlet pressure. Must be  
adjusted per Table 1.  
462 06 1211 00  
3/17/06  
-- 4 --  
 
4. Install the pressure regulator adjusting screw. This will set  
the manifold pressure close to required setting for normal  
operation.  
Typical Gas Valve Honeywell  
SV9501  
Figure 8  
Wiring Terminals  
5. Replace the regulator cap screw.  
Inlet Pressure  
Tap (Hidden)  
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.  
INLET  
Pilot  
Outlet  
D
D
Manifold Assembly -- Be sure to engage the main burner  
orifices in the proper openings in the burners.  
Pilot  
Adjustment  
Testing 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.  
OUTLET  
Outlet Pressure Tap  
Start--up and Check--out  
Connect manometer here to  
check outlet pressure. Must be  
adjusted per Table 1.  
25--22--25  
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.  
Typical Gas Valve Honeywell  
Figure 9  
VR8205S  
Regulator Adjustment  
Under Cap  
Outlet  
HONEYWELL  
3. Close manual gas line valve to unit, remove manometer and  
replace inlet pressure tap plug.  
Pressure  
Tap  
1
/ NPT  
8
Gas Valve Adjustment  
V
T
INLET  
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).  
OUTLET  
Inlet  
ON  
Pressure  
1
Tap / NPT  
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.  
8
OFF  
25--24--98a  
Typical Honeywell  
Regulator Assembly  
Figure 10  
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”.  
LP  
Natural  
Gas  
Silver  
Gas  
Cap Screw  
Black  
Pressure  
Regulator  
Adjusting  
Screw  
White White  
7. Turn gas valve to OFF. Remove the pressure gauge and re-  
place the pressure tap plug and pressure regulator cap  
screw.  
Stainless  
Steel  
8. With gas valve on, observe furnace through two or more  
complete cycles to be sure all controls are operating.  
Spring  
Red  
PRESSURE  
REGULATOR  
HOUSING  
462 06 1211 00  
3/17/06  
-- 5 --  
 
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.  
FIRE AND/OR EXPLOSION HAZARD  
Failure to follow this warning could result in personal  
injury, death, and/or property damage.  
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.  
Do NOT attempt to light the burner with a match or  
flame of any kind.  
HEATING INPUT RATE CHECK  
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:  
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. 38 sec. To complete 1 revolution  
2. 3600/38 = 94.7  
3. 94.7 x 1 = 94.7  
1. Turn off all other gas appliances that use the same  
meter.  
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).  
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.  
Required Input Rate for All Models  
Required Input Rate of Furnace Converted to Natural Gas (Btu/hr)  
Table 3  
Elevation Above Sea Level (feet)  
Heating Model  
Size1  
0-2000  
2001-3000 3001-4000 4001-5000 5001-6000 6001-7000 7001-8000 8001-9000 9001-10000  
"040" or "B"  
"060" or "C"  
"080" or "D"  
"100" or "E"  
"120" or "F"  
"140" or "G"  
1Note:  
40,000  
60,000  
35200  
52800  
70400  
88000  
105600  
123200  
33600  
50400  
67200  
84000  
100800  
117600  
32000  
48000  
64000  
80000  
96000  
112000  
30400  
45600  
60800  
76000  
91200  
106400  
28800  
43200  
57600  
72000  
86400  
100800  
27200  
40800  
54400  
68000  
81600  
95200  
25600  
38400  
51200  
64000  
76800  
89600  
24000  
36000  
48000  
60000  
72000  
84000  
80,000  
100,000  
120,000  
140,000  
For PGF3, PGX3, and PDX3 models, heating model size is indicated by the numbers in the 5th, 6th, and 7th characters in the model number.  
For PGF, PGC, PGS models, heating model size is indicated by the numbers in the 8th, 9th, and 10th characters in the model number.  
For GPFM, GPCM, and GPSM models, heating model size is indicated by the numbers in the 8th, 9th, and 10th characters in the model number.  
For PGAA, PGAD, PGCA, and PGCD models, heating model size is indicated by the letter in the 7th character in the model number.  
For PGMD and PGME models, heating model size is indicated by the letter in the 7th character in the model number.  
462 06 1211 00  
3/17/06  
-- 6 --  
 
Pilot Burner Flame Check (All models Main Burner Flame Check  
except PGF3, PGX3, and PDX3)  
Check for the following:  
3
1
Adjust flames so they surround / (9 mm) to / (13 mm) of the  
8
2
D
Stable and blue flames (See Figure 12). Dust may cause  
orange tips or wisps of yellow, but flames MUST NOT have  
solid, yellow tips.  
sensor tip (See Figure 11).  
1. Remove the cap from the pilot adjusting screw (See Fig-  
ures 7 & 8).  
D
D
Flames extending directly from burner into heat exchanger.  
Flames DO NOT touch sides of heat exchanger  
2. Turn pilot adjusting screw counterclockwise to increase,  
clockwise to decrease.  
Figure 12  
Main Burner  
3. Replace the cap on the pilot adjusting screw.  
BLUE FLAME  
Figure 11  
Pilot Burner (HSP)  
Sensor Tip  
Proper Flame  
Adjustment  
Hot Surface  
Igniter  
25--00--07a  
1 0 -- 11 -- 6 5  
462 06 1211 00  
3/17/06  
-- 7 --  
 

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