International Comfort Products CRLPELEV001A00, CRLPELEV004A00, CRLPELEV007A00, CRLPELEV009A00 Installation Manual
CRLPELEV001A00-CRLPELEV004A00
CRLPELEV007A00-CRLPELEV009A00
Installation Instructions
TABLE OF CONTENTS
PACKAGE CONTENTS 1.........................
SAFETY CONSIDERATIONS 2....................
GENERAL 2....................................
LP CONVERSION KIT INSTALLATION 3...........
Step 1 -- Remove Burner Section from Base Unit 3..........
Step 2 -- Modify Burner/Valve Assembly 3.................
Step 3 -- Re--install Burner Assembly 5....................
Step 4 -- Check Unit Operation and Make Necessary
Adjustments 6................................
SMALL ROOFTOP UNITS
ACCESSORY LP (LIQUID PROPANE)
HIGH ALTITUDE GAS CONVERSION KIT
GAS HEATING/ELECTRIC COOLING
3to15TON
60,000---350,000 Btu/hr
HIGH ALTITUDE CONVERSION KIT
INSTALLATION 7...............................
Step 1 -- Remove Burner Section from Base Unit 7..........
Step 2 -- Modify Burner/Valve Assembly 7.................
Step 3 -- Re--install Burner Assembly 7....................
Step 4 -- Check Unit Operation and Make Necessary
Adjustments 8................................
IMPORTANT: Read these instructions completely before
attempting to install this accessory.
ACCESSORY
PAR T NO.
CRLPELEV001A00
CRLPELEV002A00
CRLPELEV003A00
CRLPELEV004A00
CRLPELEV007A00
CRLPELEV008A00
CRLPELEV009A00
PACKAGE CONTENTS
LP (LIQUID PROPANE) AND HIGH ALTITUDE KIT
SIZE QTY PAR T NU M BE R
ORIFICES
31 5 LH32RF120
32 5 LH32RF116
33 5 LH32RF113
35 5 LH32RF110
36 5 LH32RF105
37 5 LH32RF104
38 5 LH32RF102
39 5 LH32RF103
44 5 LH32RF086
45 5 LH32RF082
46 5 LH32RF080
47 5 LH32RF079
48 5 LH32RF076
49 5 LH32RF073
50 5 LH32RF070
51 5 LH32RF067
52 5 LH32RF065
53 5 LH32RF060
54 5 LH32RF055
55 5 LH32RF052
36 10 LH32RF105
37 10 LH32RF104
38 10 LH32RF102
39 10 LH32RF103
40 10 LH32RF098
41 10 LH32RF096
42 10 LH32RF094
43 10 LH32RF089
51 10 LH32RF067
52 10 LH32RF065
53 10 LH32RF060
54 10 LH32RF055
55 10 LH32RF052
COMMON CONTENTS QTY PA R T N UMB E R
INSTRUCTIONS 1 I I K --- CR L P E L E V 0 1 --- 0 3
ELBOW, 1/8” NPT x 90° 1 CA05RA001 *
ELBOW, STREET1/8” NPT x 90° 1 CA15RA001 *
NIPPLE,1/8”PIPEx3/4” 1 CA01CA001 *
NIPPLE,1/8”PIPEx11/2” 1 CA01CA006 *
NIPPLE,1/8”PIPEx31/2” 1 CA01CA020 *
SWITCH, LP PRESSURE 1 HK02LB008 *
WIRE, BROWN 1 99WG7373XC200918 *
SPRINGS, LP CONVERSION 2 EF39ZW023 *
LABEL, GAS VALVE LP CONV 1 48TM501013 *
LABEL, UNIT WARNING 1 48TM501012
LABEL, LP RESPONSIBILITY 1 48TM501014 *
L A B E L , H I G H --- A LT.
RESPONSIBILITY
LABEL, LP CONVERSION KIT
RATING PLATE
LABEL, NG CONVERSION KIT
RATING PLATE
* Only used in LP applications
1 48TM501015
1 48TM502595 *
1 48TM502594
Copyright 2010 CAC / BDP D 7310 W. Morris St. D Indianapolis, IN 46231 Printed i n U.S.A. Edition Date: 06/10
Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations.
C a t a l o g N o : I I K --- C R L P E L E V 0 1 --- 0 3
R e p l a c e s : I I K --- C R L P E L E V 0 1 --- 0 2
SAFETY CONSIDERATIONS
Installation and servicing of air--conditioning equipment
can be hazardous due to system pressure and electrical
components. Only trained and qualified service personnel
should install, repair, or service air--conditioning
equipment.
Untrained personnel can perform the basic maintenance
functions. All other operations should be performed by
trained service personnel. When working on
air--conditioning equipment, observe precautions in the
literature, tags and labels attached to the unit, and other
safety precautions that may apply.
Follow all safety codes. Wear safety glasses and work
gloves.
Recognize safety information. This is the safety--alert
symbol
instructions or manuals, be alert to the potential for
personal injury.
Understand the signal words DANGER, WARNING, and
CAUTION. These words are used with the safety--alert
CRLPELEV
symbol. DANGER identifies the most serious hazards
which will result in severe personal injury or death.
WARNING signifies a hazard 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.
. When you see this symbol on the unit and in
GENERAL
These models are shipped from the factory equipped to
operate with natural gas at elevations up to 2000 ft
(610 m). The units must be modified if installed at
elevations above 2000 ft (610 m), or if operated with
liquid propane.
For installations in Canada, the input rating must be
derated by 10% for altitudes of 2000 ft (610 m) to 4500 ft
(1372 m) above sea level.
Seven different gas conversion kits are available, as
shown in Package Contents table. Each kit contains a
particular range of orifice sizes plus other hardware and
labels necessary for converting the unit. Refer to Table 1 –
Altitude Compensation to determine the recommended
orifice size based on the nominal heat size, fuel type, and
elevation. Knowing this orifice size, it is possible to select
the proper Kit Accessory Part Number from Package
Contents table.
!
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
installation 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
DOMMAGE ÀLAPROPRIÉTÉ
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.
Firing Tube
NOx Baffle
IMPORTANT: The Accessory LP Conversion is not for
use with Low NOx units. If Low NOx units are converted
to LP gas, the Low NOx baffle must be removed. (See
Fig. 1.) The unit will no longer be classified as Low NOx
units. It is suggested that the LP Conversion Kit be used
with standard units only.
C00151
Fig. 1 -- Low NOx Baffle Location
2
!
WARNING
EXPLOSION, PERSONAL INJURY HAZARD
Failure to follow this warning could result in personal
injury or death.
Two--Stage Gas Valve -- Unit is designed to operate at
a 10.0--in. wc of manifold pressure on HIGH stage and
5.0--in. wc on LOW stage with propane gas.
Single--Stage Gas Valve -- Unit is designed to operate
at a 10.0--in. wc of manifold pressure with propane gas.
!
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. Tag disconnect switch with suitable
warning label.
LP CONVERSION KIT
INSTALLATION
Step 1 — Remove Burner Section from Base
Unit
1. Shut off main gas supply to unit.
2. Shut off power to unit and install lockout tag.
3. Remove burner access panel. (See Fig. 2.)
4. Slide out burner section side panel.
5. Disconnect gas piping at unit gas valve.
6. Remove wires connected to gas valve. Mark each
wire.
7. Remove igniter and sensor wires. Mark each wire.
8. For units with burner sections as shown in Fig. 3,
remove the 2 screws that attach the burner rack to
the vestibule plate. For units with burner sections
as shown in Fig. 5, remove the 4 screws that hold
the manifold to the sheet metal brackets.
Burner Rack
Mounting Screws
(1 of 2 shown)
Fig. 3 -- Gas Section Details (Small Chassis Shown)
Attach Gas Valve
Converstion to LP
Label here
Manifold Pressure Tap
Gas Valve
Manual
Shut-off
Gas
Valve
Bracket
C08237
9. Remove the gas valve bracket.
10. Slide the burner rack or manifold out of the unit.
11. For small chassis units only----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 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.
CRLPELEV
Burner
Access
Panel
Attach Conversion Kit
Rating Plate Label Here
(Inside Panel)
Fig. 2 -- Typical Base Unit
Gas
Val ve
Attach Responsibility
Label Here
(Inside Panel)
Attach WARNING
Label Here
C09434
Step 2 — Modify Burner/Valve Assembly
1. Separate burners from frame by removing screws.
2. Remove existing gas orifices. Install the new orifices from the gas conversion kit, making sure they
match the recommended size from Table 1.
IMPORTANT: Never use Teflon tape to seal gas orifice
threads because peeling tape can plug the orifice.
3. Remount burners to support frame.
IMPORTANT: The burners should be positioned in the
same order as shipped from the factory. The crossover
flame region of the outermost burners are pinched off to
prevent excessive gas flow from the sides of the burner
assembly. If the pinched crossovers are installed between
two burners, the flame will not ignite properly.
3
CRLPELEV
4. Remove the plug on the inlet end of the gas valve
3
using a
/16--in. hex wrench. (See Fig. 4 and 6 for
units using White--Rodgers 36G gas valve and Fig.
5 and 7 for units using White--Rodgers 36H gas
valve).
C08238
Fig. 4 -- LP Pressure Switch Piping
(36G Gas Valve Shown)
5. a. For units with 36G valve, install the1/8-- i n . x
1
/2--in. nipple where the plug was removed. (See
1
Fig. 4.) Use pipe thread dope or tape (field--supplied, must be certified for use with propane gas)
for all joints, making sure not to get any excess in
1
the pipe or valve. Next, install the
1
elbow, then
/8-- i n . x3/4--in. nipple, followed by the
/8-- i n . x 9 0 _
LPPressureSwitchasshowninFig.4.
For Single--Stage Gas Valves, connect supplied
brown jumper wire from the “NO” (Normally Open)
terminal on the pressure switch to the terminal
where the gray wire was attached.
NOTE: Terminals are not marked on Gas Valve.
For Two--Stage Gas Valves, connect the supplied
brown jumper wire from the “NO” terminal on the
pressure switch to terminal “M” on the gas valve.
1
b. For units with 36H valve, install the
/8-- i n x
3/4--in nipple where the plug was removed. (See
Fig. 5.) Use pipe thread dope or tape (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 the gas valve bracket over
1
nipple, then the
1
/2--in nipple, then1/8--inx90_ street elbow,
3
/8--inx90_ elbow, then1/8-- i n x
followed by the LP Pressure Switch as shown in
Fig. 5. Connect he supplied brown jumper wire
from the “NO” terminal on the pressure switch to
terminal “MP” on the gas valve.
6. Remove regulator cover screw(s) from gas regulator(s). (See Fig. 6 or 7.) Save regulator cover screws.
7. Using a screwdriver, remove plastic adjust screw(s)
from both regulators. (See Fig. 6 or 7.) Save plastic
adjust screws.
8. Remove regulator spring(s) (silver) from gas regulator(s). (See Fig. 6 or 7.) Discard regulator springs.
9. Install propane gas regulator spring(s) (white)
shipped with the kit into the gas regulator(s). (See
Fig. 6 or 7.)
ON/OFF SWITCH
1/2˝ NPT INLET
INLET
PRESSURE TAP
1/2˝ NPT OUTLET
Fig. 5 -- LP Pressure Switch Piping
(36H Gas Valve Shown)
REGULATOR COVER SCREW
PLASTIC ADJUST SCREW
REGULATOR SPRING
(Propane - White,
Natural - Silver)
HIGH STAGE GAS
PRESSURE REGULATOR
ADJUSTMENT
LOW STAGE
GAS PRESSURE
REGULATOR ADJUSTMENT
MANIFOLD
PRESSURE TAP
Two-Stage 36G Valve
C10520
ON/OFF SWITCH
1/2˝ NPT INLET
INLET
PRESSURE TAP
1/2˝ NPT OUTLET
Fig. 6 -- 36G Valve Spring Installation
4
Single-Stage 36G Valve
REGULATOR
COVER SCREW
PLASTIC
ADJUST
SCREW
REGULATOR SPRING
(PROPANE - WHITE
NATURAL - SILVER)
GAS PRESSURE
REGULATOR
ADJUSTMENT
MANIFOLD
PRESSURE TAP
C10521
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