10
Table 5 – Single--Stage Kit Contents
ITEM
PART NO.
QUANTITY
Installation Instructions
IIKCPLPCONV---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
1
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
*Refer to Table 4 to determine the correct orifice to use.
SINGLE--STAGE KIT INTRODUCTION
These instructions cover the installation of a propane gas
conversion kit on 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
).
DESCRIPTION AND USAGE
This single--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). They cannot be used for high altitude
installation. High altitude conversion (2001--6000 ft) (610--1829
m) must use kit CPLPCONV014A00.
SINGLE--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 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 and brown wires from the gas valve
and remove blue wires from the rollout switch.
NOTE
: To locate rollout switch, see Fig. 12.
6. Disconnect orange sparker cable from the sparker.
7. Disconnect yellow flame sensor wire from the flame sensor.
8. Remove the screw securing the brown wire from the burner
assembly. Ground screw is attached to the fan partition pan-
el. 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.
12. 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 4 to select correct orifice size
based on rated input. See Fig. 13 and 15 for orifice
installation).
13. Replace the manifold/gas valve assembly into the burner
assembly using the four screws saved from item 11.
14. Remove the plug on the inlet end of the gas valve using a
3/16 in. hex wrench.
15. Install the 1/8 in. NPT x 3/4 in. (19 mm) close pipe nipple
where the plug was removed (see Fig. 19). 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. x
NPT 2 in. (51 mm) nipple, and a low gas pressure switch as
shown in Fig.19.
16. Remove regulator cover screw from the gas regulator (see
Fig. 14). Save regulator cover screw.
17. Using a screwdriver, remove the plastic regulator adjust
screw from the gas regulator (see Fig. 14). Save plastic reg-
ulator adjust screw.
18. Remove regulator spring (silver) from the gas regulator (see
Fig. 14. Discard regulator spring.
19. Install propane gas regulator spring (white) shipped with
this kit. (See Fig. 14).
20. Install plastic adjust screw into the gas regulator, turn
clockwise 13.5 turns (see Fig. 14).
CPL
P
CONV
