2
Table 1 – Two--Stage Kit Contents
ITEM
PART NO.
QUANTITY
Installation Instructions
IIK---CPLPCONV---14
1
Propane Gas Orifice #49*
LH32RF073
3
Propane Gas Orifice #51*
LH32RF067
3
Propane Gas Orifice #53*
LH32RF060
3
Propane Gas Orifice #55*
LH32RF052
3
Regulator Spring (92---0659)
EF39ZW023
2
Pressure Switch
HK02LB008
1
90
o
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)
CA01CA001
2
Wire Harness
48DU400080
1
Propane Conversion Label (Rating Plate)
48VL500206
1
Propane Conversion Label (Installer Responsibility)
48VL500207
1
Propane Conversion Warning Label (Gas Valve)
48DU500076
1
Burner Insert
48GS500465
3
*Refer to Table 4 to determine the correct orifice to use.
Firing Tube
NOx Baffle
A01051
Fig. 1 -- Low NOx Baffle Location
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 4 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 48DT, 48DU, 48XL, 48XT, 577B,
577D, 677B and 677D that are equipped with a White Rodgers
2--stage combination automatic gas valve regulator.
DESCRIPTION AND USAGE
This Two--Stage kit is applicable to units with heating inputs from
40,000 to 130,000 Btu/hr installed at standard altitudes from 0 ft to
2000 ft (0 to 610 m). It cannot be used for high altitude
installation. High altitude conversion (2001--6000 ft) (610--1829
m) must use kit CPLPCONV014A00.
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
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 and install lockout tag.
!
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 Fig. 2.
5. Disconnect the gray, blue, brown and green/yellow wires
from the gas valve and remove violet wires from the rollout
switch.
NOTE
: To locate rollout switch, see Fig. 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 parti-
tion. 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 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 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.
CPL
P
CONV
