International Comfort Products NPLPCONV014C00 Installation Manual

INSTALLATION INSTRUCTIONS

PROPANE GAS CONVERSION KIT

High Altitude Only / 2001 − 6000 FT (610−1829m)

Small Package Products / 40,000 − 130,000 Btu/hr

NPLPCONV014C00

This kit is used on:
Two −Stage Models: PGR5 (Two−Stage conversion starts on

Page 2).
Single−Stage Models: PDD3, PDS3, PGD3, PDD4, PDS4,

PGD4, PGD5, PGN4, PGN5, PGS3, PGS4, PGS5, WPG3**4,
and WPG4**4. (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.

!

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

AVERTISSEMENT

!

FEU, EXPLOSION, EMPOISONNEMENT PAR
CARBON DE MONOXYDE, RISQUE DE
DOMMAGE À LA PROPRIÉTÉ

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.

!

CAUTION

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 Figure 1). THEY MUST BE
REMOVED PRIOR TO CONVERTING THIS UNIT TO
PROPANE GAS.

Table 1 – Two−Stage Kit Contents

ITEM PART NO. QUANTITY

Installation Instructions 46206211500 1
Propane Gas Orifice #50* 1176091 3
Propane Gas Orifice #51* 1177087 3
Propane Gas Orifice #52* 1176092 3
Propane Gas Orifice #53* 1177086 3
Propane Gas Orifice #54* 1177089 3
Propane Gas Orifice #56* 1177090 3

Regulator Spring (92-0659) 1179317 2

Pressure Switch 1175469 1

90o Elbow, 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)

Wire Harness 1177091 1

Propane Conversion Label

(Rating Plate)

Propane Conversion Label

(Installer Responsibility)

Propane Conversion Warning Label

(Gas Valve)
Burner Insert 48GS500465 3
Burner Insert 50CY502897 3

*Refer to Table 5 to determine the correct orifice to use.

CA01CA001 2

50CY502880 1

50CY502881 1

1177092 1

Specifications subject to change without notice.

462 06 2115 00 11/21/2014

Firing Tube

NOx Baffle

Figure 1 − Low NOx Baffle Location

A01051

!

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 and install lockout tag. There
may be more than one disconnect switch. Lock out
and tag switch with a suitable warning label.

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 5 for proper manifold pressure
settings for high stage and low stage.

WARNING

TWO−STAGE KIT INTRODUCTION

These instructions cover the installation of a propane gas
conversion kit on models: PGR5.

DESCRIPTION AND USAGE

This Two−Stage kit is applicable to units with heating inputs from
40,000 to 130,000 Btu/hr installed at high altitudes from 2001 ft to
6000 ft (610 to 1829 m). It cannot be used for standard altitude
installation. Standard altitude conversion (0−2000 ft) (0 to 610 m)
must use kit NPLPCONV013C00.

TWO−STAGE KIT INSTALLATION

!

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

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 Figure 2.

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

NOTE: To locate rollout switch, see Figure 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 Figure 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.

2 462 06 2115 00

Specifications subject to change without notice.

Fan Partition Panel

Fan Partition
Mounting Bracket

Screw

See note below.

Screw

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.

Figure 2 − Fan Partition Bracket Removal

462 06 2115 00 3

Specifications subject to change without notice.

A09320

ROLLOUT SWITCH

(2006 − 2010 Models)

BURNER
BRACKET

C00150

Table 2 – Burner Insert Usage (40 and 60 kBtuh Units Only)

Model

PDD4**(040,060)K***D*
PDS4**(040,060)K***D*
PGD4**(040,060)K***D*
PGR5**(040,060)K***B*
PGS4**(040,060)K***D*

WPG4**4(040,060)*K**

PGR5**(040,060)(H,K)***A* 48GS500465

Burner Insert P/ N

50CY502897

A07874

(2010 − Current Models)

Figure 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 (see
Figure 7). Remove the snap ring from the end of each
burner. Refer to Table 2 for correct burner insert for specific
model. 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 Figure 7 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 5 to select correct orifice size
based on rated input and altitude. See Figure 4 and
Figure 7 for orifice installation).

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.

A07889

Figure 4 − Two−Stage Igniter, Flame Sensor, Orifice/Main

Burner Relationship

16. Install the 1/8 in. NPT x 3/4 in. (19 mm) close pipe nipple
where the plug was removed (see Figure 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. NPT x 2 in. (51 mm) nipple, and a low gas
pressure switch as shown in Figure 11.

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

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

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

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

4 462 06 2115 00

Specifications subject to change without notice.

MANIFOLD PIPE PLUG

Figure 5 − Burner Assembly

ON/OFF SWITCH

INLET
PRESSURE TAP

REGULATOR COVER SCREW

PLASTIC ADJUST SCREW

REGULATOR SPRING

(Propane - White,
Natural - Silver)

HIGH STAGE GAS
PRESSURE REGULATOR
ADJUSTMENT

LOW STAGE
GAS PRESSURE
REGULATOR ADJUSTMENT

C99019

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

31. Reconnect electrical power and gas supply to the unit. For
propane applications, the gas pressure must not be less
than 11.0 IN. W.C. or greater than 13 IN. W.C. at the unit
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

MANIFOLD
PRESSURE TAP

A07804

Figure 6 − Two−Stage Gas Valve

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

23. Verify igniter, flame sensor, orifice/main burner relationship
prior to completing conversion. (See Figure 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 Figure 8).

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

26. Reconnect orange sparker cable to sparker and reconnect
the white flame sensor wire to the flame sensor.

27. Reconnect the remaining wires removed in Step 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
Figure 2.)

29. Reconnect the brown wire from the burner assembly to the
fan partition panel, using the ground screw saved from
Step 8.

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 may result causing
property damage, personal injury or loss of life.

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 3). See Table 5 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 4 for required rated
heating input rates. Replace regulator cover screws when
finished (see Figure 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 Figure 9).

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

35. Attach warning label (P/N 1177092) to visible side of gas
valve.

36. Attach conversion label (P/N 50CY502880) above unit
rating plate on exterior of unit.

37. Attach completed conversion responsibility label (see
Figure 10, P/N 50CY502881) inside control access panel.

462 06 2115 00 5

Specifications subject to change without notice.