Carrier CPLPCONV013A00 Installation Instructions Manual

40,000--130,000 Btu/hr
Part Number:

ACCESSORY PROPANE GAS CONVERSION KIT

STANDARD ALTITUDE ONLY 0---2000 FT (0---610 m)

CPLPCONV013A00

Installation Instructions

This kit is used on:
Two--Stage (2 -- 5 Tons) Models: 48DU, 48DT, 48XL, 48XT,

577B, 577D, 677B, and 677D. (Two --Stage conversion starts on
Page 2.)

Single--Stage (1--1/2 -- 5 Tons) Models: 48ES, (“1”) series or later
(Examples: 48ES--060130311, 48ES--060130511,
48ES--060130611), 48ES--A, 48ESNA, 48EZ “1” series or later
(Examples: 48EZ--060130311, 48EZ--060130511,
48EZ--060130611), 48EZ--A, 48EZNA, 48VL, 48VT, 574D “B”
series or later (Examples: 574DNW060130NB,
574DPW060130NB, 574DEW060130NB), 574D*WA, 674D “B”
series or later (Examples: 674DNW060130NB,
674DPW060130NB, 674DEW060130NB), 674D*WA, 577C,
677C, and all PY3G except “B” series (Example:
PY3GNA060115AB). (Single--Stage conversion starts on Page

10.)
NOTE: Read the entire instruction manual before starting the

installation.

SAFETY CONSIDERATIONS

Improper installation, adjustment, alteration, service maintenance,
or use can cause explosion, fire, electrical shock, or other
conditions which may cause death, personal injury, or property
damage. Consult a qualified installer, service agency, or your
distributor or branch for information or assistance. The qualified
installer or agency must use factory--authorized kits or accessories
when modifying this product. Refer to the individual instructions
packaged with the kits or accessories when installing.

Follow all safety codes. Wear safety glasses, protective clothing,
and work gloves. Have a fire extinguisher available. Read these
instructions thoroughly and follow all warnings or cautions
included in literature and attached to the unit. consult local
building codes, the current editions of the National Fuel Gas Code
(NFGC) NFPA 54/ANSI Z223.1, and the National Electrical Code
(NEC) NFPA 70.

In Canada refer to the current editions of the National Standards of
Canada CAN/CSA--B149.1 and .2 Natural Gas and Propane
Installation codes, and Canadian Electrical Code CSA C22.1

Recognize safety information. This is the safety--alert symbol
When you see this symbol on the unit and in instructions or manu­als, be alert to the potential for personal injury. Understand these
signal words: DANGER, WARNING, and CAUTION. These
words are used with the safety--alert symbol. DANGER identifies
the most serious hazards which will result in severe personal injury
or death. WARNING signifies hazards which could result in per­sonal injury or death. CAUTION is used to identify unsafe practic­es which may result in minor personal injury or product and prop­erty damage. NOTE is used to highlight suggestions which will
result in enhanced installation, reliability, or operation.

SMALL PACKAGED P RODUCTS

!

WARNING

FIRE, EXPLOSION, CARBON MONOXIDE
POISONING, PROPERTY DAMAGE HAZARD

Failure to follow this warning could result in personal
injury, death 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. The qualified service agency is
responsible for the proper installatio n of this kit. The
installation is not proper and complete until the operation of
the converted furnace is checked as specified in the
manufacturer ’s instructions supplied in the kit.

AVERTISSEMENT

!

FEU, EXPLOSION, EMPOISONNEMENT PAR
CARBON DE MONOXYDE, RISQUE DE
DOMMAGEÀLAPROPRIÉTÉ

La négligeance de suivre l’avis suivant, peut causer des
blessures personnelles, la mort ou du dommage à la
propriété.

Cette trousse de conversion doit être installée par un
Entrepreneur qualifié, selon les instructions du fabricant et
doit se conformer à toutes les exigences et tout les codes
pertinents de l’autorité compétente. L’Entrepreneur qualifié
est responsable, et doit s’assurer de bien suivre les
instructions dans cet avis. L’installation sera considèrèè
conforme et rencontrant les spécifications et instructions du
fabriquant qui sont inclus dans la trousse, seulement aprés
vérification de l’opération de la fournaise convertie.

!

.

UNIT OPERATION HAZARD

Failure to follow this caution may result in damage to unit
components.

Before converting a unit to propane gas, remove the burner
assembly and inspect the heat exchanger tubes. If there are
V-- shaped NOx baffles installed in the firing tubes, (see
Fig. 1). THEY MUST BE REMOVED PRIOR TO
CONVERTING THIS UNIT TO PROPANE GAS.

CAUTION

1

Propane Gas Orifice #49* LH32RF073 3
Propane Gas Orifice #51* LH32RF067 3
Propane Gas Orifice #53* LH32RF060 3
Propane Gas Orifice #55* LH32RF052 3

Regulator Spring (92--- 0659) EF39ZW023 2

Nipple,1/8in.NPTx2in.(51mm) CA01CA010 1

ClosePipeNipple,1/8in.NPTx3/4in.(19mm) CA01CA001 2

Propane Conversion Label (Rating Plate) 48VL500206 1

Propane Conversion Label (Installer Responsibility) 48VL500207 1

Propane Conversion Warning Label (Gas Valve) 48DU500076 1

*Refer to Table 4 to determine the correct orifice to use.

Firing Tube

CPLPCONV

Table 1 – Two--Stage Kit Contents

ITEM PAR T NO. QUANTITY

Installation Instructions I I K --- C P L P C O N V --- 1 4 1

Pressure Switch HK02LB008 1

90oElbow, 1/8 in. NPT CA05RA001 2

Wire Harness 48DU400080 1

Burner Insert 48GS500465 3

!

WARNING

ELECTRICAL SHOCK HAZARD

Failure to follow this warning could result in personal
injury or death.

Before installing or servicing system, always turn off main

NOx Baffle

power to system. There may be more than one disconnect
switch and install lockout tag.

A01051

Fig. 1 -- Low NOx Baffle Location

!

WARNING

EXPLOSION, PERSONAL INJURY HAZARD

Failure to follow this warning could result in personal
injury or death.

This unit is designed to operate at a minimum 10.0 IN. W.C.
of manifold pressure on high stage with propane gas. Refer
to Table 4 for proper manifold pressure settings for high
stage and low stage.

TWO--STAGE KIT INTRODUCTION

These instructions cover the installation of a propane gas
conversion kit on models 48DT, 48DU, 48XL, 48XT, 577B,
577D, 677B and 677D that are equipped with a White Rodgers
2--stage combination automatic gas valve regulator.

DESCRIPTION AND USAGE

This Two-- Stage kit is applicable to units with heating inputs from
40,000 to 130,000 Btu/hr installed at standard altitudes from 0 ft to
2000 ft (0 to 610 m). It cannot be used for high altitude
installation. High altitude conversion (2001--6000 ft) (610--1829
m) must use kit CPLPCONV014A00.

TWO--STAGE KIT INSTALLATION

!

WARNING

FIRE, EXPLOSION, ELECTRICAL HAZARD

Failure to follow this warning could result in personal
injury, death or property damage.

Gas supply MUST be shut off before disconnecting
electrical power and proceeding with conversion.

1. Turn off gas supply first, then power to unit.

2. Remove the control access panel from unit.

3. Disconnect the gas pipe from the gas valve.

4. Remove the screw attaching the gas manifold to the
basepan, and partially slide out the entire burner rack
assembly from unit. Save screw. The fan partition mounting
bracket may be removed for easier access to the burner
assembly. The bracket may be removed by removing 2
screws (located on the left side of the control compartment
on the fan partition panel) and sliding the bracket forward,
bottom first. See Fig. 2.

5. Disconnect the gray, blue, brown and green/yellow wires
from the gas valve and remove violet wires from the rollout
switch.

NOTE: To locate rollout switch, see Fig. 3.

6. Disconnect orange sparker cable from the sparker.

7. Disconnect white flame sensor wire from the flame sensor.

8. Remove the ground screw securing the brown wire from the
burner assembly. Ground screw is attached to the fan parti­tion. Save screw.

9. Completely slide out the entire burner rack assembly from
unit.

10. Inspect the inlet of the heat exchanger tubes for presence of
V-- shaped NOx baffles (see Fig. 1). If baffles are present,
they must be removed prior to converting unit for propane
gas. Using needle--nose pliers, remove NOx baffles, squeeze
sides of the baffle, if necessary, to remove from the heat
exchanger tubes.

IMPORTANT: If it is expected that this unit will be converted
back to natural gas at a later time, these baffles should be retained
for reuse. Otherwise the baffles may be discarded.

11. Using a 5/16 in. nut driver, remove the four screws securing
the manifold/gas valve assembly to the burner assembly.
Save these screws.

2

Fan Partition Panel

Fan Partition
Mounting Bracket

Screw

See note below.

Screw

CPLPCONV

NOTE:

The fan partition bracket may be removed for easier access
to the burner assembly. The bracket may be removed by
removing 2 screws on the control side and sliding the bracket
forward, bottom first.

If the fan partition bracket was removed, slide bracket back into
place and fasten with 2 screws.

Fig. 2 -- Fan Partition Bracket Removal

A09320

3

CPLPCONV

ROLLOUT SWITCH

BURNER
BRACKET

C00150

(2006 -- 2010 Models)

A07874

(2010 -- Current Models)

Fig. 3 -- Two--Stage Burner Bracket

12. For 2--stage 40,000 Btu/hr and 60,000 Btu/hr only! Remove
the burners from the rack, save the screws. Remove the snap
ring from the end of each burner. Install burner insert in the
end of each burner with the flat sides of the square vertical
and horizontal. Replace the snap ring to retain burner insert
(see Fig 6 for correct orientation). Replace the burners in the
rack using the saved screws, making sure closed crossovers
of burners are at each end.

13. Remove the natural gas orifices from the manifold using a
9/16 in. wrench and install the correct propane gas orifices
in the manifold (See Table 4 to select correct orifice size
based on rated input. See Fig. 4 and 7 for orifice
installation).

A07889

Fig. 4 -- Two--Stage Igniter, Flame Sensor, Orifice/Main

Burner Relationship

14. Replace the manifold/gas valve assembly into the burner
assembly using the four screws saved from item 11.

15. Remove the plug on the inlet end of the gas valve using a
3/16 in. hex wrench.

16. Install the 1/8 in. NPT x 3/4 in. (19 mm) close pipe nipple
where the plug was removed (see Fig. 11). Use pipe thread
dope (field-- supplied, must be certified for use with propane
gas) for all joints, making sure not to get any excess in the
pipe or valve. Next, install a 1/8 in. elbow, a 1/8 in. NPT x
3/4 in. (19 mm) close pipe nipple, 1/8 in. elbow, 1/8 in. x
NPT 2 in. (51 mm) nipple, and a low gas pressure switch as
shown in Fig. 11.

17. Remove regulator cover screws for both high and low stage
gas regulators (see Fig. 6). Save regulator cover screws.

18. Using a screwdriver, remove plastic adjust screws from both
high and low stage gas regulators (see Fig. 6). Save plastic
adjust screws.

19. Remove regulator springs (silver) from both high and low
stage gas regulators (see Fig. 6). Discard regulator springs.

20. Install propane gas regulator springs (white) shipped with
this kit. One into the low stage gas regulator and one into
the high stage gas regulator (see Fig. 6).

21. Install plastic adjust screw into the high stage gas regulator.
turn clockwise 13.5 turns (see Fig. 6).

4

MANIFOLD PIPE PLUG

C99019

Fig. 5 -- Two--Stage Burner Assembly

REGULATOR COVER SCREW

ON/OFF SWITCH

INLET
PRESSURE TAP

PLASTIC ADJUST SCREW

REGULATOR SPRING

(Propane - White,
Natural - Silver)

HIGH STAGE GAS
PRESSURE REGULATOR
ADJUSTMENT

LOW STAGE
GAS PRESSURE
REGULATOR ADJUSTMENT

MANIFOLD
PRESSURE TAP

A07804

Fig. 6 -- Two--Stage Gas Valve

22. Install plastic adjust screw into the low stage gas regulator.
turn clockwise 9.5 turns (see Fig. 6).

23. Verify igniter, flame sensor, orifice/main burner
relationship p rior to completing conversion. (See Fig. 4.)
Partially slide burner rack assembly into unit.

24. Disconnect the orange wire from the combustion air
pressure switch and connect it to the orange wire on the low
gas pressure switch (LGPS) equipped with a 1/4 in. male
quick--connect terminal. The low gas pressure switch
should have one unconnected orange wire remaining.
Connect this wire to the vacant terminal on the combustion
air pressure switch (see Fig. 8).

25. Reconnect the violet wires removed in item 5 to the rollout
switch and reinstall the rollout switch.

26. Reconnect orange sparker cable to sparker and reconnect
thewhiteflamesensorwiretotheflamesensor.

27. Reconnect the remaining wires removed in item 5 to the gas
valve. Connect the gray wires to (HI). Connect the blue
wires to (M). Connect the brown and green/yellow wires to
(C).

28. Slide burner rack assembly into base pan. Align burner rack
with screws on sheet metal partition and slide assembly
back tight to the partition. Replace the screw attaching the
burner rack to the base pan removed in step 4. If the Fan
partition mounting bracket was removed, slide bracket back
into placed and fasten with 2 screws. (See Fig. 2.)

29. Reconnect the brown wire from the burner assembly to the
fan partition panel, using the ground screw saved from Step

8.

30. Remove the 1/8 in. pipe plug on the gas manifold and
connect a pressure manometer (see Fig. 5).

31. Reconnect electrical power and gas supply to the unit. For
propane applications, the gas pressure must not be less than

11.0IN.W.C.orgreaterthan13IN.W.C.attheunit
connection. A 1/8--in. NPT plugged tapping, accessible for
test gauge connection, must be installed immediately
upstream of the gas supply connection to the gas valve and
downstream of manual equipment shutoff valve.

The newly installed low gas pressure switch is a safety device used
to guard against adverse burner operating characteristics that can
result from low gas supply pressure. Switch opens at not less than

6.5 IN. W.C. and closes at not greater than 10.2 IN. W.C.
This switch also prevents operation when the propane tank level is

low which can result in gas with a high concentration of impurities,
additives, and residues that have settled to the bottom of the tank.
Operation under these conditions can cause harm to the heat
exchanger system.

This normally open switch closes when gas is supplied to gas valve
under normal operating pressure. The closed switch completes
control circuit. Should an interruption or reduction in gas supply
occur, the gas pressure at switch drops below low gas pressure
switch setting, and switch opens. Any interruption in control
circuit (in which low gas pressure switch is wired) quickly closes
gas valve and stops gas flow to burners.

!

WARNING

FIRE AND EXPLOSION HAZARD

Failure to follow this warning could result in personal
injury and/or property damage.

Never test for gas leaks with an open flame. Use a
commercially available soap solution made specifically for
the detection of leaks to check all connections.

IMPORTANT: Restart unit and leak check all gas connections
including the main service connection, gas valve, gas spuds, and
manifold pipe plug. All leaks must be repaired before firing unit.

32. Fire unit and verify proper ignition and proper sequence of
operation (Table 2). See Table 4 for proper low stage and
high stage manifold pressure settings for your unit. Adjust
the gas valve setting for high and low stages by turning the
plastic adjustment screws clockwise to increase pressure and
counter--clockwise to decrease pressure for the respective
stages. Refer to Table 3 for required rated heating input
rates. Replace regulator cover screws when finished (see
Fig. 6).

33. With control access panel removed, observe unit heating
operation in both low stage operation and high stage opera­tion. Watch burner flames to see if they are blue in appear­ance, and that the flames are approximately the same for
each burner (see Fig. 9).

34. Turn off unit, remove pressure manometer and replace the
1/8 in. pipe fitting on the gas manifold (see Fig. 5).

35. Attach warning label (P/N 48DU500076) to visible side of
gas valve.

36. Attach conversion label (P/N 48VL500206) above unit
rating plate on exterior of unit.

37. Attach completed conversion responsibility label (see Fig.
10, P/N 48VL500207) inside control access panel.

CPLPCONV

5

K

MANIFOLD

FLAME
SENSOR

CLOSED END

BURNER (3)

CLOSED END

BURNER RAC

CPLPCONV

PIPE PLUG

PIPE PLUG

HI

M

C

ON

C

LO

HI

SPARKER

OFF

GAS VALVE

ORIFICE (3)

TWO-STAGE 90,000 BTUH TO 130,000 BTUH UNITS

BURNER INSERT (3)

CLOSED END

FLAME
SENSOR

CLOSED END

MANIFOLD

BURNER RACK

SPARKER

HI

M

C

ON

C

OFF

LO

HI

ORIFICE (3)

GAS VALVE

SNAP RING (3)

BURNER (3)

ORIENTATION
OF BURNER
INSERT

A08565

PIPE PLUG

FLAME SENSOR

MANIFOLD

ORIFICE (2)

TWO-STAGE

60,000 BTUH

BURNER INSERT (2)

CLOSED END

UNITS

SNAP RING (2)

SPARKER

HI

M

C

ON

C

OFF

LO

TWO-STAGE

HI

40,000 BTUH UNITS

GAS VALVE

Fig. 7 -- Two--Stage Orifice Installation

6

BURNER (2)

CLOSED END

BURNER RACK

ORIENTATION
OF BURNER
INSERT

A08509

FURNACE CONTROL BOARD

Y

PLUG P1

1 2 3 4 5 6 7 8 9 10 11 12

YEL

ORN ORN

LGPS

CAPS

LEGEND
ORN = ORANGE

EL = YELLOW
LGPS = LOW GAS PRESSURE SWITCH
CAPS = COMBUSTION AIR PRESSURE SWITCH

= QUICK CONNECTION

A06487

Fig. 8 -- Pressure Switch Wiring for Two --Stage Units

Table 2 – Two--Stage Sequence of Operations

Inducer Pre--Purge Period: When the inducer motor comes up on high speed, the pressure switch closes, and the Infinityt ignition control
on the furnace board begins a 15 sec pre-- purge period. If the pressure switch fails to remain closed, the inducer will remain running. After
the pressure switch recloses, the Infinity ignition control will begin a 15 sec pre--purge period.

Trial--for--Ignition Sequence: The spark igniter will spark for 3 sec, the main gas valve relay contact closes to energize the gas valve on low
stage. After 5 sec, the igniter is de--energized and a 2--sec flame--proving period begins.

NOTE: The unit always lights on high speed inducer and low stage gas valve operation.

Flame--Proving: When the burner flame is proved at the flame--proving sensor, the furnace control determines what heating stage to run
based on feedback from the User Interface (UI). If the UI is asking for low stage gas heat, the ignition control will change the inducer speed
to low speed and keep the gas valve energized on low stage. If the UI is asking for high stage gas heat, the ignition control will maintain
running the inducer on high speed and energize the gas valve’s high stage relay to increase gas flow.

CPLPCONV

Table 3 – Two--Stage Rated Heating Input, Propane Gas (0--2000 ft [0-- 610 m] Altitude)

NAMEPLATE INPUT , H IGH STAGE (BTU/HR)

40,000 38,000 26,000

60,000 57,000 39,000

90,000 79,000 58,500

115,000 103,000 75,000
130,000 116,000 84,500

RATED HEATING INPUT PROPANE (BTU/HR)

HIGH STAGE LOW STAG E

BURNER FLAME

(Blue in appearance)

BURNER

MANIFOLD

C99021

Fig. 9 -- Monoport Burner

7

IMPORTANT: Restart unit and leak check all gas connections
including the main service connection, gas valve, gas spuds, and
manifold pipe plug.

38. After all leaks are eliminated, replace control access panel.

!

WARNING

CPLPCONV

!

WARNING

FIRE AND EXPLOSION HAZARD

Failure to follow this warning could result in personal
injury and/or property damage.

Never test for gas leaks with an open flame. Use a
commercially available soap solution made specifically for
the detection of leaks to check all connections. A fire or
explosion could result causing property damage, personal
injury and/or loss of life.

EXPLOSION, PERSONAL INJURY HAZARD

Failure to follow this warning could result in personal
injury or death.

This unit is designed to operate at a minimum 10.0 IN. W.C.
of manifold pressure with propane gas. Refer to Table 4 for
proper manifold pressure settings.

Fig. 10 -- Conversion Responsibility Label

Table 4 – Propane Gas Orifice Sizes and Manifold Pressures (IN. W.C.)

A08491

A08564

8

TWO

-STAGE GAS VALVE
1/8 NPTx 3/4 IN. (19.1 MM) CLOSE PIPE NIPPLE

1/8 NPTx 3/4 IN. (19.1 MM) CLOSE PIPE NIPPLE

1/8 ELBOW

HI

M

ON

C

C

LO

HI

OFF

1/8 ELBOW

1/8 NPTx 2 IN. (50.8 MM) NIPPLE

CPLPCONV

LOW GAS PRESSURE SWITCH

Fig. 11 -- Installing Elbows, Nipples, and Pressure Switch on Two--Stage Units

A09016

9

ITEM PAR T NO. QUANTITY

Install ation In structions IIKCPLPCONV--- 14 1
Propane Gas Orifice #49* LH32RF073 3
Propane Gas Orifice #51* LH32RF067 3
Propane Gas Orifice #53* LH32RF060 3
Propane Gas Orifice #55* LH32RF052 3

Regulator Spring (92---0659) EF39ZW023 1

Pressure Switch HK02LB008 1

90oElbow, 1/8 in. NPT CA05RA001 2

Nipple, 1/8 in. NPT x 2 in. (51 mm) CA01CA010 1

Close Pipe Nipple, 1/8 in. NPT x 3/4 in. (19 mm) CA01CA001 2

Propane Conversion Label (Rating Plate) 48VL500206 1

Propane Conversion Label (Installer Responsibility) 48VL500207 1

Propane Conversion Warning Label (Gas Valve) 48DU500076 1

*Refer to Table 4 to determine the correct orifice to use.

Wire Harness 48DU400080 1

SINGLE--STAGE KIT INTRODUCTION

These instructions cover the installation of a propane gas
conversion kit on models 48ES “1” series or later (Examples:
48ES--060130311, 48ES--060130511, 48ES--060130611),
48ES--A, 48ESNA, 48EZ “1” series or later (Examples:
48EZ--060130311, 48EZ--060130511, 48EZ--060130611),
48EZ--A, 48EZNA, 48VL, 48VT, 574D “B” series or later
(Examples: 574DNW060130NB, 574DPW060130NB,

CPLPCONV

574DEW060130NB), 574D*WA, 674D “B” series or later
(Examples: 674DNW060130NB, 674DPW060130NB,
674DEW060130NB), 674D*WA, 577C, 677C, and all PY3G

except “B” series (Example: PY3GNA060115AB).

DESCRIPTION AND USAGE

This single--stage kit is applicable to units with heating inputs from
40,000 to 130,000 Btu/hr installed at standard altitudes from 0 ft to
2000 ft. (0 to 610 m). They cannot be used for high altitude
installation. High altitude conversion (2001--6000 ft) (610--1829
m) must use kit CPLPCONV014A00.

SINGLE--STAGE KIT INSTALLATION

!

WARNING

FIRE, EXPLOSION, ELECTRICAL HAZARD

Failure to follow this warning could result in personal
injury, death or property damage.

Gas supply MUST be shut off before disconnecting
electrical power and proceeding with conversion.

!

WARNING

ELECTRICAL SHOCK HAZARD

Failure to follow this warning could result in personal
injury or death.

Before installing or servicing system, always turn off main
power to system. There may be more than one disconnect
switch and install lockout tag.

1. Turn off gas supply first, then power to unit.

2. Remove the control access panel from unit.

3. Disconnect the gas pipe from the gas valve.

4. Remove the screw attaching the gas manifold to the
basepan, and partially slide out the entire burner rack
assembly from unit. Save screw. The fan partition mounting
bracket may be removed for easier access to the burner
assembly. The bracket may be removed for easier access to
the burner assembly. The bracket may be removed by
removing 2 screws (located on the left side of the control
compartment on the fan partition panel) and sliding the
bracket forward, bottom first. See Fig. 2.)

Table 5 – Single--Stage Kit Contents

5. Disconnect the gray and brown wires from the gas valve
and remove blue wires from the rollout switch.

NOTE: To locate rollout switch, see Fig. 12.

6. Disconnect orange sparker cable from the sparker.

7. Disconnect yellow flame sensor wire from the flame sensor.

8. Remove the screw securing the brown wire from the burner
assembly. Ground screw is attached to the fan partition pan­el. Save screw.

9. Completely slide out the entire burner rack assembly from
unit.

10. Inspect the inlet of the heat exchanger tubes for presence of
V-- shaped NOx baffles (see Fig. 1). If baffles are present,
they must be removed prior to converting unit for propane
gas. Using needle--nose pliers, remove NOx baffles, squeeze
sides of the baffle, if necessary, to remove from the heat
exchanger tubes.

IMPORTANT: If it is expected that this unit will be converted
back to natural gas at a later time, these baffles should be retained
for reuse. Otherwise the baffles may be discarded.

11. Using a 5/16 in. nut driver, remove the four screws securing
the manifold/gas valve assembly to the burner assembly.
Save these screws.

12. Remove the natural gas orifices from the manifold using a
9/16 in. wrench and install the correct propane gas orifices
in the manifold (See Table 4 to select correct orifice size
based on rated input. See Fig. 13 and 15 for orifice
installation).

13. Replace the manifold/gas valve assembly into the burner
assembly using the four screws saved from item 11.

14. Remove the plug on the inlet end of the gas valve using a
3/16 in. hex wrench.

15. Install the 1/8 in. NPT x 3/4 in. (19 mm) close pipe nipple
where the plug was removed (see Fig. 19). Use pipe thread
dope (field-- supplied, must be certified for use with propane
gas) for all joints, making sure not to get any excess in the
pipe or valve. Next, install a 1/8 in. elbow, a 1/8 in. NPT x
3/4 in. (19 mm) close pipe nipple, 1/8 in. elbow, 1/8 in. x
NPT 2 in. (51 mm) nipple, and a low gas pressure switch as
shown in Fig.19.

16. Remove regulator cover screw from the gas regulator (see
Fig. 14). Save regulator cover screw.

17. Using a screwdriver, remove the plastic regulator adjust
screw from the gas regulator (see Fig. 14). Save plastic reg­ulator adjust screw.

18. Remove regulator spring (silver) from the gas regulator (see
Fig. 14. Discard regulator spring.

19. Install propane gas regulator spring (white) shipped with
this kit. (See Fig. 14).

20. Install plastic adjust screw into the gas regulator, turn
clockwise 13.5 turns (see Fig. 14).

10

Rollout Switch

CPLPCONV

Fig. 12 -- Single--Stage Burner Bracket

21. Verify igniter, ignitor, flame sensor, orifice/main burner
relationship prior to completing conversion. (See Fig. 13.)
Partially slide burner rack assembly into unit.

22. Disconnect the orange wire from the combustion air
pressure switch and connect it to the orange wire on the low
gas pressure switch (LGPS) equipped with a 1/4 in. male
quick--connect terminal. The low gas pressure switch
should have one unconnected orange wire remaining.
Connect this wire to the vacant terminal on the combustion
air pressure switch (see Fig. 16).

ON/OFF SWITCH

1/2" NPT INLET

INLET
PRESSURE TAP

Burner Bracket

REGULATOR

COVER SCREW

PLASTIC

ADJUST

SCREW

REGULATOR SPRING
(PROPANE - WHITE
NATURAL - SILVER)

GAS PRESSURE
REGULATOR
ADJUSTMENT

A07874

A07890

Fig. 13 -- Single--Stage Igniter, Flame Sensor, Orifice/Main

Burner Relationship

11

1/2" NPT OUTLET

Fig. 14 -- Single--Stage Gas Valve

MANIFOLD
PRESSURE TAP

A07808

Y

CPLPCONV

Single-Stage 90,000 BTUH to

130,000 BTUH Units

Fig. 15 -- Single--Stage Orifice Installation

FURNACE CONTROL BOARD

PLUG J2

1 2 3 4 5 6 7 8 9 10 11 12

CAPS

YEL

LEGEND
ORN = ORANGE

EL = YELLOW
LGPS = LOW GAS PRESSURE SWITCH
CAPS = COMBUSTION AIR PRESSURE SWITCH

= QUICK CONNECTION

Fig. 16 -- Pressure Switch Wiring for Single--Stage Units

Single-Stage 40,000 BTUH to

60,000 BTUH Units

ORN

ORN

LGPS

ORN

A07873

A07806

12

23. Reconnect the blue wires removed in item 5 to the rollout
switch and reinstall the rollout switch.

24. Reconnect orange sparker cable to sparker and reconnect
the yellow flame sensor wire to the flame sensor.

25. Reconnect the gray and brown wires removed in item 5 to
the gas valve.

26. Slide burner rack assembly into base pan. Align burner rack
with screws on sheet metal partition and slide assembly
back tight to the partition. Replace the screw attaching the
burner rack to the base pan removed in step 4. If the fan
partition mounting bracket was removed, slide bracket back
into place and fasten with 2 screws (see Fig. 2).

27. Reconnect the brown wire from the burner assembly to the
fan partition panel, using the ground screw saved from step

8.

28. Remove the 1/8 in. pipe plug on the gas manifold and
connect a pressure manometer (see Fig. 17).

29. Reconnect electrical power and gas supply to the unit. For
propane applications, the gas pressure must not be less than

11.0IN.W.C.orgreaterthan13IN.W.C.attheunit
connection. A 1/8--in. NPT plugged tapping, accessible for
test gauge connection, must be installed immediately
upstream of the gas supply connection to the gas valve and
downstream of manual equipment shutoff valve.

The newly installed low gas pressure switch is a safety device used
to guard against adverse burner operating characteristics that can
result from low gas supply pressure. Switch opens at not less than

6.5 IN. W.C. and closes at not greater than 10.2 IN. W.C.
This switch also prevents operation when the propane tank level is

low which can result in gas with a high concentration of impurities,
additives, and residues that have settled to the bottom of the tank.
Operation under these conditions can cause harm to the heat
exchanger system.

This normally open switch closes when gas is supplied to gas valve
under normal operating pressure. The closed switch completes
control circuit. Should an interruption or reduction in gas supply
occur, the gas pressure at switch drops below low gas pressure
switch setting, and switch opens. Any interruption in control
circuit (in which low gas pressure switch is wired) quickly closes
gas valve and stops gas flow to burners.

!

WARNING

FIRE AND EXPLOSION HAZARD

Failure to follow this warning could result in personal
injury and/or property damage.

Never test for gas leaks with an open flame. Use a
commercially available soap solution made specifically for
the detection of leaks to check all connections.

IMPORTANT: Restart unit and leak check all gas connections
including the main service connection, gas valve, gas spuds, and
manifold pipe plug. All leaks must be repaired before firing unit.

30. Fire unit and verify proper ignition and proper sequence of
operation (Table 6). See Table 4 for proper manifold pres­sure setting for your unit. Adjust the gas valve setting by
turning the plastic adjustment screws clockwise to increase
pressure and counter--clockwise to decrease pressure. Refer
to Table 7 for required rated heating input rates. Replace
regulator cover screws when finished (see Fig. 14).

31. With control access panel removed, observe unit heating
operation. Watch burner flames to see if they are blue in ap­pearance, and that the flames are approximately the same for
each burner (see Fig. 18).

32. Turn off unit, remove pressure manometer and replace the
1/8 in. pipe fitting on the gas manifold (see Fig. 17).

33. Attach warning label (P/N 48DU500076) to visible side of
gas valve.

34. Attach conversion label (P/N 48VL500206) above unit
rating plate on exterior of unit.

35. Attach completed conversion responsibility label (see Fig.
10, P/N 48VL500207) inside control access panel.

IMPORTANT: Restart unit and leak check all gas connections
including the main service connection, gas valve, gas spuds, and
manifold pipe plug.

!

WARNING

FIRE AND EXPLOSION HAZARD

Failure to follow this warning could result in personal
injury and/or property damage.

Never test for gas leaks with an open flame. Use a
commercially available soap solution made specifically for
the detection of leaks to check all connections.

CPLPCONV

36. After all leaks are eliminated, replace control access panel.

13

Table 6 – Single--Stage Sequence of Operations

Trial--for--Ignition Sequence: The ignition sequence is to immediately energize the inducer motor on a call for heat. Within approximately 5
sec of the call for heat, the gas valve will open and the igniter will spark. Seven sec will be allowed to prove flame sense on the far burner.

Flame--Proving: Once flame is proven, the control will wait an additional 45 sec to energize the indoor blower motor. On removal of the call
for heat, the gas valve will immediately shut down, the inducer motor will run for an additional 5 sec, and the indoor blower will run for an
additional 45 sec (minimum).

Table 7 – Single--Stage Rated Heating Input, Propane Gas (0--2000 ft (0--610 m) Altitude)

NAMEPLATE INPUT (BTU/H R) RATED HEATING INPUT PROPANE (BTU/HR)

40,000 38,000

60,000 53,000

90,000 79,000

115,000 103,000
130,000 116,000

CPLPCONV

Pipe Plug

Manifold

A07872

Fig. 17 -- Single--Stage Burner Assembly

BURNER FLAME

(Blue in appearance)

BURNER

MANIFOLD

A07805

Fig. 18 -- Monoport Burner

14

LOW GAS PRESSURE SWITCH

1/8 NPTx 2 IN. (50.8 MM) NIPPLE

SINGLE-STAGE GAS VALVE

1/8 ELBOW

1/8 NPTx 3/4 IN. (19.1 MM) CLOSE PIPE NIPPLE

1/8 NPTx 3/4 (19.1MM) CLOSE PIPE NIPPLE

CPLPCONV

Fig. 19 -- Installing Elbows, Nipples, and Pressure Switch on Single--Stage Units

A09017

15

CPLPCONV

Copyright 2010 CAC / BDP D 7310 W. Morris St. D Indianapolis, IN 46231 Printed i n U.S.A. Edition Date: 04/10

Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.

16

Catalog No: IIK---CPLPCONV---14

Replaces: IIKCPLPCONV---12