International Comfort Products CRLPELEV001A00, CRLPELEV004A00, CRLPELEV007A00, CRLPELEV009A00 Installation Manual
High Altitude Gas Conversion Kit
Gas Heating/Electric Cooling
3 to 15 Ton Small Rooftop Units
Accessory LP (Liquid Propane)
Installation Instructions
PART NO. CRLPELEV001A00-CRLPELEV004A00,
CRLPELEV007A00-CRLPELEV009A00
TABLE OF CONTENTS
PACKAGE CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . .2
LP (Liquid Propane) Kit. . . . . . . . . . . . . . . . . . . . . . . . .2
High Altitude Kit (Natural Gas) . . . . . . . . . . . . . . . . . .2
SAFETY CONSIDERATIONS . . . . . . . . . . . . . . . . . . . .2
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
LP CONVERSION KIT INSTALLATION . . . . . . . . . . .4
Step 1 — Remove Burner Section
from Base Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Step 2 — Modify Burner/Valve Assembly . . . . . . . .5
Step 3 — Re-install Burner Assembly. . . . . . . . . . . .6
Step 5 — Check Unit Operation
and Make Necessary Adjustments . . . . . . . . . . . .8
HIGH ALTITUDE CONVERSION KIT
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Step 1 — Remove Burner Section from
Base Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Step 2 — Modify Burner/Valve Assembly . . . . . . . .8
Step 3 — Re-install Burner Assembly. . . . . . . . . . . .8
Step 4 — Check Unit Operation and
Make Necessary Adjustments . . . . . . . . . . . . . . . .9
IMPORTANT: Read these instructions completely
before attempting to install this accessory.
Table 1 — Unit Usage
CARRIER MODELS
Check positions 7-8 on unit dataplate for unit size.
MODEL UNIT SIZES NOMINAL TONS
48FC 04-07 3-6
48GC 04-06 3-5
48TC 08-16 7.5-15
48HC 07-14 6 -12.5
48KC 04-06 3-5
48LC 04-12 3-10
BRYANT MODELS
Check positions 6-7 on unit dataplate for unit size.
MODEL UNIT SIZES NOMINAL TONS
582K 04-07 3-6
581K 04-06 3-5
580J 08-16 7.5-15
581J 07-14 6-12.5
582J 04-06 3-5
ICP MODELS
Check positions 6-7 on unit dataplate for unit size.
MODEL UNIT SIZES NOMINAL TONS
RGV 036-072 3-6
RGW 036-060 3-5
P
RGS 089-180 7.5-15
RGH 072-150 6-12.5
RGX 036-060 3-5
IMPORTANT: The accessories described in this installation instructions manual are suitable for use on the
models listed below. DO NOT ATTEMPT TO
INSTALL ON MODELS AND SIZES NOT
INCLUDED IN THESE TABLES.
Catalog No. 04-53480200-01 Printed in U.S.A. Form IIK-CRLPELEV01-07 Pg 1 8-18 Replaces: IIK-CRLPELEV01-06
Manufacturer reserves the right to discontinue, or change at any time, specifications or designs without notice and without incurring obligations.
PACKAGE CONTENTS
LP (Liquid Propane) Kit
ACCESSORY PART NO.
CRLPELEV003A00
(LP Only)
CRLPELEV004A00
(LP Only)
CRLPELEV009A00
(LP Only)
COMMON CONTENTS QTY PART NUMBER
ELBOW, 1/8” NPT x 90° 1 CA05RA001
ELBOW, STREET 1/8” NPT x 90° 1 CA15RA001
NIPPLE, 1/8” PIPE x 3/4” 1 CA01CA001
NIPPLE, 1/8” PIPE x 1-1/2” 1 CA01CA006
NIPPLE, 1/8” PIPE x 3-1/2” 1 CA01CA020
SWITCH, LP PRESSURE 1 HK02LB008
WIRE, BROWN 1 99WG7373XC200918
SPRINGS, LP CONVERSION 2 EF39ZW023
LABEL, LP CONVERSION KIT
RATING PLATE
LABEL, LP RESPONSIBILITY 1 48TM501014
LABEL, HIGH-ALT.
RESPONSIBILITY
Package Contents CRLPELEV003 and 004A00 Only
CRLPELEV003, 004A00 ONLY QTY PART NUMBER
LABEL, GAS VALVE LP CONV 1 48TM501013
LABEL, UNIT WARNING (LP) 1 48TM501012
Package Contents CRLPELEV009A00 Only
CRLPELEV009A00 ONLY QTY PART NUMBER
LABEL, GAS VALVE LP CONV 1 48TM504835
LABEL, UNIT WARNING (LP) 1 48TM504836
SWITCH, TEMPERATURE
ACTUATED
SIZE QTY PART NUMBER
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
51 10 LH32RF067
52 10 LH32RF065
53 10 LH32RF060
54 10 LH32RF055
55 10 LH32RF052
ORIFICES
1 48TM502595
1 48TM501015
1 HH18HA147
High Altitude Kit (Natural Gas)
ACCESSORY PART NO.
CRLPELEV001A00
(Natural Gas Only)
CRLPELEV002A00
(Natural Gas Only)
CRLPELEV007A00
(Natural Gas Only)
CRLPELEV008A00
(Natural Gas Only)
COMMON CONTENTS QTY PART NUMBER
LABEL, HIGH-ALT.
RESPONSIBILITY
LABEL, NG CONVERSION KIT
RATING PLATE
SIZE QTY PART NUMBER
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
36 10 LH32RF105
37 10 LH32RF104
38 10 LH32RF102
39 10 LH32RF103
40 10 LH32RF098
41 10 LH32RF096
42 10 LH32RF094
43 10 LH32RF089
ORIFICES
1 48TM501015
1 48TM502594
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 . When you see this symbol on the unit and in 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 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.
2
GENERAL
FIRING TUBE
NOx BAFFLE
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 Tables 2-5 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.
IMPORTANT: If Low NOx units are converted to LP gas, the
Low NOx baffle must be removed. (See Fig. 1.) The converted unit will no longer be classified as a Low NOx unit. For installation simplicity, it is suggested that the LP Conversion
Kit be used with standard units only.
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.
WARNING
EXPLOSION, PERSONAL INJURY HAZARD
Failure to follow this warning could result in personal inju-
ry or death.
Two-Stage Gas Valve - Unit is designed to operate at see
Tables 6-8 of manifold pressure with propane gas.
Single-Stage Gas Valve - Unit is designed to operate at a
10.-in. wc of manifold pressure with propane gas.
Fig. 1 — Low NOx Baffle Location
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.
WARNING
FIRE, EXPLOSION, ELECTRICAL HAZARD
Failure to follow this warning could result in personal inju-
ry, death or property damage.
Gas supply MUST be shut off before disconnecting electri-
cal power and proceeding with conversion.
WARNING
ELECTRICAL SHOCK HAZARD
Failure to follow this warning could result in personal inju-
ry 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.
3
WARNING
GAS VALVE
INLET PRESSURE
TAP SET SCREW
MANIFOLD
GAS VALVE
MANIFOLD PRESSURE
TAP SET SCREW
FIRE HAZARD
Failure to follow this warning could result in personal
injury, death, and/or property damage.
Inlet pressure tap set screw must be tightened and
1
/8-in. NPT pipe plug must be installed to prevent gas leaks.
WARNING
FIRE HAZARD
Failure to follow this warning could result in personal
injury, death, and/or property damage.
Manifold pressure tap set screw must be tightened and
1
/8-in. NPT pipe plug must be installed to prevent gas leaks.
Attach Responsibility
Label Here
(Inside Panel)
Attach WARNING
Label Here
Burner
Access
Panel
Attach Conversion Kit
Rating Plate Label Here
(Inside Panel)
Gas
Val ve
Fig. 2 — Typical Base Unit
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. 4
and 5 remove the 4 screws that hold the manifold to the
sheet metal brackets.
BURNER RACK
MOUNTING SCREWS
(1 OF 2 SHOWN)
Attach Gas Valve
Converstion to LP
Label here
GAS VALVE
MANUAL SHUTOFF
GAS VALV E
BRACKET
Check that your unit model number agrees with Table 1.
LP CONVERSION KIT INSTALLATION
IMPORTANT: Before starting installation of this accessory, check your unit’s dataplate for model and size and
compare to the Unit Usage table on page 1. If your unit’s
size designation exceeds the largest size listed for your
model, STOP. This accessory is not for use on your unit.
Consult with your sales office for the correct accessory
part number for use on your unit.
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.)
MANIFOLD
PRESSURE
TA P
Fig. 3 — Gas Section Details (Small Chassis Shown)
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.
4
Step 2 — Modify Burner/Valve Assembly
SINGLE STAGE AND TWO STA GE
HIGH REGULATOR COVER SCREW
REGULATOR ADJUST SCREW
REGULATOR SPRING
OUTLET PRESSURE TAP
REGULATOR ADJUST SCREW
LOW REGULATOR COVER SCREW
(TWO STAGE ONLY)
REGULATOR SPRING
PILOT COVER SCREW
PILOT GASKET
PILOT ADJUST SCREW
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 Tables 2-5.
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.
4. Remove the plug on the inlet end of the gas valve using a
3
/16-in. hex wrench. (See Fig. 4 and 7 for units using
White-Rodgers 36G gas valve and Fig. 5 and 6 for units
using White-Rodgers 36H gas valve).
Fig. 4 — LP Pressure Switch Piping (36G Gas Valve
Shown)
1
5. a. For units with 36G valve, install the
/8-in. x 11/2-in.
nipple where the plug was removed. (See 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 the pipe or valve. Next, install
1
the
/8-in. x 90 degree elbow, then 1/8-in. x 3/4-in. nipple,
followed by the LP Pressure Switch as shown in Fig. 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.
b. For units with 36H valve, install the
1
/8-in. 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 nipple, then the
elbow, then
1
/8-in. x 31/2-in. nipple, then 1/8-in. x 90
1
/8-in. x 90 degree
degree street elbow, followed by the LP Pressure Switch
as shown in Fig. 5. Connect the 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. 7 or 6.) Save regulator cover screws.
7. Using a screwdriver, remove plastic adjust screw(s) from
both regulators. (See Fig. 7 or 6.) Save plastic adjust
screws.
8. Remove regulator spring(s) (silver) from gas regulator(s). (See Fig. 7 or 6.) Discard regulator springs.
9. Install propane gas regulator spring(s) (white) shipped
with the kit into the gas regulator(s). (See Fig. 7 or 6.)
10. For two-stage gas valves, install plastic adjust screw into
the high stage gas regulator, turn clockwise 13.5 turns.
(See Fig. 7 or 6.) Then install plastic adjust screw into
the low stage gas regulator, turn clockwise 9.5 turns.
Replace regulator cover screws. (See Fig. 7 or 6.)
For single-stage gas valves, install plastic adjust screw
into the single-stage gas regulator, turn clockwise 13.5 turns.
Replace regulator cover screw. (See Fig. 7.)
Fig. 5 — LP Pressure Switch Piping (36H Gas Valve
Shown)
Fig. 6 — Two-Stage Spring Installation (36H Gas
Valve Shown)
5
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