Reznor CAUA Manuel utilisateur

Revision: CP-CAUA-GC (04-21) 170635-A

GAS CONVERSION KIT INSTALLATION FOR GAS-FIRED INDOOR

HEATER

Supersedes: CP-CAUA-GC (01-18) PN170635R9

MODEL CAUA

GENERAL INFORMATION

The gas conversion kits in these instructions are for model CAUA heaters equipped with speciﬁc single-stage or

two-stage gas valves. The kits are for operation at sea level. When converting a unit with a two-stage valve (option

AG2), check for the valve manufacturer. If the unit has a two-stage White-Rodgers valve, a new two-stage gas valve

is required.

Gas Valve Identiﬁcation

In order to verify which conversion kit is compatible with your heater, it is necessary to know the type of gas valve on

the heater. Refer to the unit rating plate for the complete model number of the heater. Also, refer to the manufacturer’s

name and number found on the gas valve. Match the model number of the valve to the one listed in the kit—if different,

contact your manufacturer representative to select and verify parts required for gas conversion.

Important Safety Information

Please read all information in this manual thoroughly and become familiar with the capabilities and use of your

appliance before attempting to operate or maintain this unit. Pay attention to all dangers, warnings, cautions, and

notes highlighted in this manual. Safety markings should not be ignored and are used frequently throughout to

designate a degree or level of seriousness.

DANGER: A danger statement describes a potentially hazardous situation that if not avoided, will result in severe

personal injury or death and/or property damage.

WARNING: A warning statement describes a potentially hazardous situation that if not avoided, can result in severe

personal injury and/or property damage.

CAUTION: A caution statement describes a potentially hazardous situation that if not avoided, can result in minor

or moderate personal injury and/or property damage.

NOTE: A note provides important information that should not be ignored.

⚠ DANGER ⚠

FIRE OR EXPLOSION HAZARD

• Failure to follow safety warnings exactly could result in serious injury, death, or property

damage.

• Improper installation,adjustment,alteration, service,or maintenance can cause serious injury,

death, or property damage.

• Installation and service must be performed by a qualiﬁed installer, service agency, or the gas

supplier.

• Do not store or use gasoline or other ﬂammable vapors and liquids in the vicinity of this or

any other appliance.

WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.

• Do not touch any electrical switch; do not use any phone in your building.

• Leave the building immediately.

• Immediately call your gas supplier from a neighbor’s phone. Follow the gas supplier’s

instructions.

• If you cannot reach your gas supplier, call the ﬁre department.

DO NOT DESTROY. PLEASE READ CAREFULLY. KEEP IN A SAFE PLACE FOR FUTURE REFERENCE.

2CP-CAUA-GC (04-21) 170635-A

GENERAL INFORMATION—CONTINUED

Important Safety Information—Continued

⚠ DANGER ⚠

• The conversion kit is to be selected and installed by a qualiﬁed service person in accordance

with these instructions and in compliance with all codes and requirements of authorities having

jurisdiction. Failure to follow instructions could result in death, serious injury ,and/or property

damage. The qualiﬁed agency performing this work assumes responsibility for this conversion.

• Improper installation,adjustment,alteration,service,or maintenance can cause property damage,

injury, or death. Read the installation, operation, and maintenance instructions thoroughly before

installing or servicing this equipment.

• FOR YOUR SAFETY: Do not store or use gasoline or other ﬂammable vapors and liquids in the

vicinity of this or any other appliance.

• The gas burner in this gas-ﬁred equipment is designed and equipped to provide safe, complete

combustion. However, if the installation does not permit the burner to receive the proper supply

of combustion air, complete combustion may not occur. The result is incomplete combustion,

which produces carbon monoxide, a poisonous gas that can cause death.

• Safe operation of indirect-ﬁred gas burning equipment requires a properly-operating vent system

that vents all ﬂue products to the outside atmosphere. FAILURE TO PROVIDE PROPER VENTING

WILL RESULT IN A HEALTH HAZARD THAT COULD CAUSE SERIOUS PERSONAL INJURY OR

DEATH.

• If installed as a separated-combustion system, install either the horizontal or vertical combustion

air/vent system illustrated in the heater installation manual,using the concentric adapter supplied.

All installations must comply with the combustion air requirements in the installation codes

and instructions. Units installed in a conﬁned space must be supplied with air for combustion

and ventilation as required by code and in the heater installation manual. Combustion air at the

burner should be regulated only by manufacturer-provided equipment. NEVER RESTRICT OR

OTHERWISE ALTER THE SUPPLY OF COMBUSTION AIR TO ANY HEATER. MAINTAIN THE VENT

SYSTEM IN PROPERLY-OPERATING CONDITION.

NOTE: In Canada, gas conversion shall be carried out in accordance with the requirements of the

Provincial Authorities having jurisdiction and in accordance with the requirements of CSA-B149.1

and .2 installation code.

CONVERSION KIT SELECTION

NOTES:

• Refer to Table 1 for a list of natural gas (NG) to propane (LP) conversion kit components.

• Refer to Table 2 for a list of propane to natural gas conversion kit components.

• Refer to Table 3 for burner oriﬁces included in the gas conversion kits (for sea-level operation

only) and for replacement oriﬁces for high-elevation (>2,000 feet) installations.

• Refer to Table 4 for a list of additional components required for converting a unit equipped with a

two-stage White-Rodgers (WR) gas valve. When converting a unit with a two-stage valve (option

AG2), check for the valve manufacturer. If equipped with a Honeywell (HW) valve, select the kit

listed in Table 1 and Table 2.

• All kits include the quantity of oriﬁces required for the largest size of heater. Extra burner oriﬁces

may not be returned for credit.

CP-CAUA-GC (04-21) 170635-A

Table 1. Natural Gas to Propane Conversion Kit Components

Unit

Size

Kit

PN Component*Description PN Gas Valve

(Model No.

All

NG to LP spring kit HW #393691 for single-stage valve VR8105, VR8205, or VR8305 98720

—Tape Conversion 64391

Disk Propane 37752

150

269833

NG to LP spring kit HW #396221 for single-stage valve VR8215

260605

Single-stage (HW

VR8304M2816

#VR8205M1130, or

#VR8215S1263)

two-stage (HW

#VR8204Q2418)

Spring regulator kit HW #

396021

for two-stage valve

197207

200 269834

NG to LP spring kit HW #396221 for single-stage valve VR8215

260605

Spring regulator kit HW #

396021

for two-stage valve

197207

250 170815 Spring regulator kit WR #F920659 for single-stage WR valve 82524

Single-stage (WR

#36C68-452,

#36H32-441, or HW

#VR8305M4009)

two-stage (HW

#VR8304Q4404)

HW #396021 for two-stage valve 197207

300 170816 Spring regulator kit WR #F920659 for single-stage WR valve 82524

HW #396021 for two-stage valve 197207

350 170817 Spring regulator kit WR #F920659 for single-stage WR valve 82524

HW #396021 for two-stage valve 197207

400 170818 Spring regulator kit WR #F920659 for single-stage WR valve 82524

HW #396021 for two-stage valve 197207

*Burner oriﬁces are include in each kit. Refer to Table 3 for oriﬁce PN, size, and quantity.

Table 2. Propane to Natural Gas Conversion Kit Components

Unit

Size

Kit

PN Component*Description PN Gas Valve

(Model No.

All

LP to NG spring kit HW #

394588

for single-stage valve VR8105, VR8205, or VR8305 98721

—Tape Conversion 64391

Disk Natural Gas 1401

150

269833

LP to NG spring kit HW #396222 for single-stage valve VR8215 261651 Single-stage (HW

#VR8204M1018,

#VR8205M1148, or

#VR8215S5215)

two-stage (HW

#VR8304Q4412)

Spring conversion kit HW #3906025 for two-stage valve

197208

200 269834

LP to NG spring kit HW #396222 for single-stage valve VR8215 261651

Spring conversion kit HW #3906025 for two-stage valve

197208

250,

300 170810 Spring conversion kit WR #92-0656 for single-stage WR valve 82525 Single-stage (WR

#36C68-325,

#36H32-442, or HW

#VR8305M4819)

two-stage (HW

#VR8304Q4412)

HW #396025 for two-stage valve 197208

350 170811 Spring conversion kit WR #92-0656 for single-stage WR valve 82525

HW #396025 for two-stage valve 197208

400 170812 Spring conversion kit WR #92-0656 for single-stage WR valve 82525

HW #396025 for two-stage valve 197208

*Burner oriﬁces are include in each kit. Refer to Table 3 for oriﬁce PN, size, and quantity.

Table 3. Burner Oriﬁces

Installation

Elevation (Feet)

Installation

Location Unit Size Natural Gas Propane Quantity

PN Size PN Size

0–2000 US or Canada

150 164866 2.10 mm 97359 1.25 mm 8

200

11833 #44

11830 #55 10

250 97359 1.25 mm 13

300 11830 #55 15

350 11835 #37 9789 #53 12

400 45870 #38 61653 1.55 mm 14

2001–3000 US

150 84853 #47 97359 1.25 mm 8

200

38678 #45

11830 #55 10

250 97359 1.25 mm 13

300 11830 #55 15

350 45870 #38 11834 #54 12

400 45871 #39 9789 #53 14

Table 3. Burner Oriﬁces

Installation

Elevation (Feet)

Installation

Location Unit Size Natural Gas Propane Quantity

PN Size PN Size

2001–4500 Canada

150 40414 #48 63003 1.20 mm 8

200

38678 #45

11830 #55 10

250 63003 1.20 mm 13

300 11830 #55 15

350 45871 #39 11834 #54 12

400 11792 #41 61652 1.45 mm 14

3001–4000 US

150 84853 #47 63003 1.20 mm 8

200

38678 #45

11830 #55 10

250 63003 1.20 mm 13

300 11830 #55 15

350 45871 #39 11834 #54 12

400 87391 #40 9789 #53 14

4001–5000 US

150 40414 #48 63003 1.20 mm 8

200

38678 #45

11830 #55 10

250 63003 1.20 mm 13

300 11830 #55 15

350 45871 #39 11834 #54 12

400 11792 #41 61652 1.45 mm 14

5001–6000 US

150 40414 #48 63003 1.20 mm 8

200

16590 #46

39658 #56 10

250 63003 1.20 mm 13

300 39658 #56 15

350 87391 #40 11834 #54 12

400 11792 #41 61652 1.45 mm 14

6001–7000 US

150 40414 #48

39658 #56

200

84583 #47

250 13

300 15

350 11792 #41 11834 #54 12

400 84437 #42 61652 1.45 mm 14

7001–8000 US

150 39651 #49 63922 1.15 mm 8

200

84583 #47

39658 #56 10

250 63922 1.15 mm 13

300 39658 #56 15

350 84437 #42 11834 #54 12

400 14

8001–9000 US

150 39651 #49 63922 1.15 mm 8

200

40414 #48

39658 #56 10

250 63922 1.15 mm 13

300 39658 #56 15

350 84437 #42 11830 #55 12

400 11828 #43 11834 #54 14

CONVERSION KIT SELECTION—CONTINUED

—Continued

Table 4. Components Required for Converting Unit with Two-Stage White-Rodgers Gas Valve

Unit

Size

Two-Stage Gas Valve Brass

Plug

Reducing Bushing

(3/4- to 1/2-Inch)*

Natural Gas Propane

150 177396

177398 107367

37385

200

250

177397 —

300

350

400

*Used only for natural gas to propane conversions.

4CP-CAUA-GC (04-21) 170635-A

INSTALLATION

Install the conversion kit in accordance with the following steps. Ensure that the kit (refer to Table 1 or Table 2) is

correct for the size of the heater being serviced. Heater component locations are shown in Figure 1.

Figure 1. Heater Components

NOTE: Conversion using these kits will not alter the input rate. Refer to the rating plate on the unit

for the input rate and other appropriate information.

1. Remove gas supply and electrical power:

a. Turn OFF gas supply at shutoff valve upstream of combination gas valve.

b. Turn OFF electrical power.

c. Open control access panel.

2. Install regulator spring kit:

⚠ WARNING ⚠

Regulator spring kits are not interchangeable. Each kit must be used only in the model and type of

gas valve for which the kit is designated.Verify compatibility before installing the regulator spring kit.

a. Select regulator spring kit that corresponds with gas valve on heater. All gas conversion kits include one or

two regulator spring kits for single-stage valve and one regulator spring for two-stage valve. Other included

regulator spring kits will not be used.

b. Install regulator spring kit in accordance with gas valve manufacturer’s instructions (included with regulator

spring kit).

NOTE: Depending on when the unit was manufactured, there will be either two or three burner

covers. If two, there will be right and left covers that extend over the front of the unit. If three, there

will be right and left covers and a separate front cover.

CP-CAUA-GC (04-21) 170635-A

6CP-CAUA-GC (04-21) 170635-A

INSTALLATION—CONTINUED

NOTE: When converting a unit with a two-stage White-Rodgers gas valve the spring kits in the

conversion kit will not be used and the gas valve requires replacing.

3. For units with White-Rodgers two-stage gas valve, replace valve:

a. Disconnect gas valve wires from existing valve. Label wires for correct reconnection.

b. Disconnect existing gas valve from gas supply line and remove valve.

NOTE: Because the unit does not have a pilot, the pilot port on the replacement two-stage White-

Rodgers gas valve needs to be plugged using a brass plug.

c. Using brass plug listed in Table 4, plug port labeled “pilot” on replacement valve listed in Table 4.

⚠ WARNING ⚠

The operating gas valve is the primary safety shutoff. The gas supply line must be free of dirt or

scale before connecting the valve.

d. Connect inlet side of replacement gas valve to gas supply line. Do not connect valve to manifold.

e. Connect gas valve wires labelled in step 3b to valve.

f. Ensure that all gas valve connections are in accordance with unit wiring diagram and valve manufacturer’s

instructions.

4. Replace burner oriﬁces:

a. Remove all burner covers and disconnect manifold from valve.

b. Remove screws that secure manifold assembly and remove manifold assembly from heater.

c. Carefully remove existing burner oriﬁces.

d. For all conversions, select replacement burner oriﬁces in accordance with Table 3.

⚠ WARNING ⚠

Do not attempt to drill burner oriﬁce. Use factory-supplied oriﬁce only.

e. Install replacement burner oriﬁces.

⚠ CAUTION ⚠

Ensure that the manifold is positioned properly with relation to the burner rack.

f. Install manifold assembly in heater and secure using screws removed in step 4b.

g. Attach conversion disk to heater near gas valve.

h. Connect manifold to valve. For natural gas to propane conversion of unit size 150 or 200 with White-Rodgers

two-stage gas valve, use reducing bushing listed in Table 4 to connect valve.

i. Install burner cover removed in step 4a.

5. Perform leak test:

a. Turn ON gas supply at shutoff valve upstream of combination gas valve.

b. Check between shutoff valve and combination gas valve for gas leaks using commercial leak-detecting ﬂuid

or rich soap and water solution. Leaks are indicated by presence of bubbles.

c. If leak is detected, tighten connection. If leak cannot be stopped by tightening connection, replace part(s).

d. When no leaks are detected, turn OFF gas supply at shutoff valve upstream of combination gas valve.

6. Restore electrical power and gas supply:

a. Turn ON electrical power.

b. Turn ON gas supply and relight heater in accordance with instructions on heater.

CP-CAUA-GC (04-21) 170635-A

c. Recheck all manifold connections for gas leaks in accordance with step 5.

7. Measure and adjust manifold (outlet) pressure:

⚠ WARNING ⚠

Manifold gas pressure must never exceed 3.5 IN WC for natural gas or 10 IN WC for propane.

Incorrect inlet pressure could cause excessive manifold gas pressure.

a. Ensure that inlet (supply) pressure is in accordance with Table 5 and determine correct manifold (outlet)

pressure (refer to Table 5).

Table 5. Gas Pressure Requirements

Natural Gas Propane

Minimum Maximum Minimum Maximum

Inlet (Supply) Pressure (IN WC)

5.0*14.0 11.0*14.0

Single-Stage and Two-Stage High-Fire Two-Stage Low-Fire

Natural Gas Propane Natural Gas Propane

Manifold (Outlet) Pressure (IN WC)

3.5 10.0 1.8 5.0

*Or as stated on the unit rating plate.

b. Turn knob or switch on top of valve to OFF to prevent ﬂow to gas valve.

NOTE: A manometer (ﬂuid-ﬁlled gauge) is recommended rather than a spring-type gauge due to

the difﬁculty of maintaining the calibration of a spring-type gauge. Use a water column manometer

that is readable to the nearest tenth of an inch.

c. Connect manometer to 1/8-inch output pressure tap on valve (see Figure 2).

SINGLE-STAGE VALVES

TWO-STAGE VALV E

REGULATOR

SCREW

INLET

PRESSURE

TA P

1/8" OUTLET

PRESSURE

TA P

1/8" OUTLET

PRESSURE

TA P

INLET

PRESSURE

TA P

REGULATOR

SCREW

INLET PRESSURE TA P

1/8" OUTLET PRESSURE TA P

HIGH-FIRE

REGULATOR SCREW

LOW-FIRE

REGULATOR SCREW

Figure 2. Gas Valves

INSTALLATION—CONTINUED

⚠ CAUTION ⚠

DO NOT bottom out the gas valve regulator screw. This can result in excessive overﬁre and heat

exchanger failure due to unregulated manifold pressure.

d. To measure/adjust high ﬁre pressure on single-stage or two-stage valve:

(1) Turn knob or switch on top of valve to ON.

(2) If pressure is out-of-range, remove cap from regulator screw (see Figure 2) and adjust pressure in accordance

with Table 5 by turning regulator screw IN (clockwise) to increase pressure or OUT (counterclockwise)

to decrease pressure.

e. To measure/adjust low ﬁre pressure on two-stage valve:

(1) Disconnect wire from HI terminal on gas valve.

(2) Remove cap from low-ﬁre regulator screw (see Figure 2) and adjust pressure in accordance with Table

5 by turning regulator screw IN (clockwise) to increase pressure or OUT (counterclockwise) to decrease

pressure.

(3) Reconnect wire to Hi terminal on gas valve.

⚠ WARNING ⚠

In the event of improper ignition, wait at least 5 minutes before attempting to relight the heater.

f. Turn up thermostat and cycle burner once or twice to properly seat adjustment spring in valve.

g. Recheck outlet pressure. When pressure corresponds to Table 5, disconnect manometer and install cap on

regulator screw.

h. Check for leakage at 1/8-inch outlet pressure tap ﬁtting. Correct as necessary.

8. Operate heater for at least one complete cycle to check for proper operation. Observe main burners for

complete ﬂame carryover.

9. Fill out conversion tape and adhere to clean, dry surface near unit rating plate.

10. Close control access panel.

Speciﬁcations and illustrations subject to change without notice or incurring obligations.

CP-CAUA-GC (04-21) 170635-A

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