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1

40,000--130,000 Btu/hr

Part Number:

CPLPCONV013A00

Installation Instructions

SMALL PACKAGED PRODUCTS

ACCESSORY PROPANE GAS CONVERSION KIT

STANDARD ALTITUDE ONLY 0---2000 FT (0---610 m)

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--0601303

1

1, 48ES--0601305

1

1,

48ES--0601306

1

1), 48ES--A, 48ESNA, 48EZ “1” series or later

(Examples: 48EZ--0601303

1

1, 48EZ--0601305

1

1,

48EZ--0601306

1

1), 48EZ--A, 48EZNA, 48VL, 48VT, 574D “B”

series or later (Examples: 574DNW060130N

B

,

574DPW060130N

B

, 574DEW060130N

B

), 574D*WA, 674D “B”

series or later (Examples: 674DNW060130N

B

,

674DPW060130N

B

, 674DEW060130N

B

), 674D*WA, 577C,

677C, and all PY3G

except

“B” series (Example:

PY3GNA060115A

B

). (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.

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

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.

!

AVERTISSEMENT

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

!

Summary of Contents for CPLPCONV013A00

Page 1: ...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 identifi...

Page 2: ...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 in...

Page 3: ...er 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...

Page 4: ...e 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 s...

Page 5: ...re 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 grea...

Page 6: ...E ORIFICE 2 FLAME SENSOR MANIFOLD 40 000 BTUH UNITS CLOSED END PIPE PLUG CLOSED END BURNER 3 BURNER RACK SPARKER FLAME SENSOR ORIFICE 3 MANIFOLD 60 000 BTUH PIPE PLUG CLOSED END GAS VALVE LO HI O FF O...

Page 7: ...igniter is de energized and a 2 sec flame proving period begins NOTE The unit always lights on high speed inducer and low stage gas valve operation Flame Proving When the burner flame is proved at the...

Page 8: ...ks to check all connections A fire or explosion could result causing property damage personal injury and or loss of life WARNING 38 After all leaks are eliminated replace control access panel EXPLOSIO...

Page 9: ...8 NPTx 3 4 IN 19 1 MM CLOSE PIPE NIPPLE 1 8 ELBOW 1 8 ELBOW 1 8 NPTx 3 4 IN 19 1 MM CLOSE PIPE NIPPLE 1 8 NPTx 2 IN 50 8 MM NIPPLE LOW GAS PRESSURE SWITCH TWO A09016 Fig 11 Installing Elbows Nipples...

Page 10: ...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 bott...

Page 11: ...on 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...

Page 12: ...Fig 15 Single Stage Orifice Installation 1 2 3 4 5 6 7 8 9 10 11 12 LGPS PLUG J2 FURNACE CONTROL BOARD LEGEND ORN ORANGE YEL YELLOW LGPS LOW GAS PRESSURE SWITCH CAPS COMBUSTION AIR PRESSURE SWITCH ORN...

Page 13: ...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...

Page 14: ...l 45 sec to energize the indoor blower motor On removal of the call for heat the gas valve will immediately shut down the inducer motor will run for an additional 5 sec and the indoor blower will run...

Page 15: ...ELBOW LOW GAS PRESSURE SWITCH 1 8 NPTx 2 IN 50 8 MM NIPPLE 1 8 NPTx 3 4 19 1MM CLOSE PIPE NIPPLE 1 8 NPTx 3 4 IN 19 1 MM CLOSE PIPE NIPPLE A09017 Fig 19 Installing Elbows Nipples and Pressure Switch o...

Page 16: ...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 Catalog No IIK CP...

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