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
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