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40,000- -130,000 Btu/hr
Part Number:
CPLPCONV013A00
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 manu-
als, 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 per-
sonal injury or death. CAUTION is used to identify unsafe practic-
es which may result in minor personal injury or product and prop-
erty damage. NOTE is used to highlight suggestions which will
result in enhanced installation, reliability, or operation.
ACCESSORY PROPANE GAS CONVERSION KIT
STANDARD ALTITUDE ONLY 0---2000 FT (0---610 m)
Installation Instructions
SMALL PACKAGED PRODUCTS
WARNING
!
FIRE,
EXPLOSION,
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,
CARBON
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.
!
.
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.
1
CARBON
MONOXIDE
EMPOISONNEMENT
MONOXYDE,
RISQUE
CAUTION
PAR
DE
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Summary of Contents for Carrier CPLPCONV013A00
- Page 1 40,000- -130,000 Btu/hr SMALL PACKAGED PRODUCTS ACCESSORY PROPANE GAS CONVERSION KIT Part Number: STANDARD ALTITUDE ONLY 0---2000 FT (0---610 m) CPLPCONV013A00 Installation Instructions This kit is used on: WARNING Two- -Stage (2 - - 5 Tons) Models: 48DU, 48DT, 48XL, 48XT, 577B, 577D, 677B, and 677D.
-
Page 2: Description And Usage
Table 1 – Two- -Stage Kit Contents ITEM PART NO. QUANTITY Installation Instructions IIK--- CPLPCONV--- 14 Propane Gas Orifice #49* LH32RF073 Propane Gas Orifice #51* LH32RF067 Propane Gas Orifice #53* LH32RF060 Propane Gas Orifice #55* LH32RF052 Regulator Spring (92--- 0659) EF39ZW023 Pressure Switch HK02LB008... - Page 3 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.
- Page 4 ROLLOUT SWITCH BURNER BRACKET C00150 (2006 - - 2010 Models) 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.
-
Page 5: Fire And Explosion Hazard
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. - Page 6 CLOSED END BURNER (3) FLAME SENSOR CLOSED END MANIFOLD BURNER RACK PIPE PLUG SPARKER GAS VALVE ORIFICE (3) TWO-STAGE 90,000 BTUH TO 130,000 BTUH UNITS A08565 BURNER INSERT (3) CLOSED END ORIENTATION OF BURNER INSERT FLAME SENSOR SNAP RING (3) BURNER (3) CLOSED END MANIFOLD...
- Page 7 FURNACE CONTROL BOARD PLUG P1 1 2 3 4 5 6 7 8 9 10 11 12 CAPS LGPS LEGEND ORN = ORANGE YEL = YELLOW LGPS = LOW GAS PRESSURE SWITCH CAPS = COMBUSTION AIR PRESSURE SWITCH = QUICK CONNECTION A06487 Fig.
- Page 8 IMPORTANT: Restart unit and leak check all gas connections 38. After all leaks are eliminated, replace control access panel. including the main service connection, gas valve, gas spuds, and WARNING manifold pipe plug. WARNING EXPLOSION, PERSONAL INJURY HAZARD Failure to follow this warning could result in personal FIRE AND EXPLOSION HAZARD injury or death.
-
Page 9: Low Gas Pressure Switch
-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 1/8 ELBOW 1/8 NPTx 2 IN. (50.8 MM) NIPPLE LOW GAS PRESSURE SWITCH A09016 Fig. 11 - - Installing Elbows, Nipples, and Pressure Switch on Two- -Stage Units... -
Page 10: Electrical Shock Hazard
Table 5 – Single- -Stage Kit Contents ITEM PART NO. QUANTITY Installation Instructions IIKCPLPCONV ---14 Propane Gas Orifice #49* LH32RF073 Propane Gas Orifice #51* LH32RF067 Propane Gas Orifice #53* LH32RF060 Propane Gas Orifice #55* LH32RF052 Regulator Spring (92 ---0659) EF39ZW023 Pressure Switch HK02LB008 Elbow, 1/8 in. - Page 11 Rollout Switch Burner Bracket A07874 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.
- Page 12 Single-Stage 90,000 BTUH to Single-Stage 40,000 BTUH to 130,000 BTUH Units 60,000 BTUH Units A07873 Fig. 15 - - Single- -Stage Orifice Installation FURNACE CONTROL BOARD PLUG J2 1 2 3 4 5 6 7 8 9 10 11 12 CAPS LGPS LEGEND...
- Page 13 23. Reconnect the blue wires removed in item 5 to the rollout WARNING switch and reinstall the rollout switch. 24. Reconnect orange sparker cable to sparker and reconnect the yellow flame sensor wire to the flame sensor. FIRE AND EXPLOSION HAZARD 25.
- Page 14 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.
- Page 15 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 A09017 Fig. 19 - - Installing Elbows, Nipples, and Pressure Switch on Single- -Stage Units...
- Page 16 Catalog No: IIK---CPLPCONV ---14 Copyright 2010 CAC / BDP D 7310 W. Morris St. D Indianapolis, IN 46231 Printed in U.S.A. Edition Date: 04/10 Manufacturer reserves the right to change, at any time, specifications and designs without notice and without obligations. Replaces: IIKCPLPCONV--- 12...