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Installation Instructions This kit is used on: Two-Stage (2 - 5 Tons) Models: 48DU, 577B, 577D, 677B, and 677D. (Two-Stage 48DT, 48XL, 48XT, conversion starts on Page 2.) Single-Stage (1-1/2 - 5 Tons) 48VT, 574D, 577C, 674D, conversion starts on Page 9.) NOTE: Read installation. the entire SAFETY Models: 677C, 48ES, 48EZ, and PY3G. instruction manual 48VL, Failure to follow this iniury, death or property (Single-Stage before starting the CONSIDERATIONS Improper installation, adjustment, alteration, service maintenance, or use can cause explosion, fire, electrical shock, or other conditions which may cause death, personal iniury, or property damage. Consult a qualified installer, service agency, distributor or branch for information or assistance. The FIRE, EXPLOSION, POISONING, PROPERTY or your qualified CARBON DAMAGE warning damage. could MONOXIDE HAZARD result in personal 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. 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. and work gloves. Have instructions thoroughly included in literature building codes, and follow and attached the current (NFGC) NFPA 54/ANSI (NEC) NFPA 70. In Canada Canada Wear safety glasses, protective clothing, a fire extinguisher available. Read these editions Z223.1, refer to the current CAN/CSA-BI49.1 Installation codes, Recognize safety and information. or cautions consult local of the National and the National editions and Canadian all warnings to the unit. Fuel Gas Code Electrical of the National .2 Natural Electrical Gas Code Standards and symbol z_X 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 sonal injury or death. La n_gligeance de suivre l'avis blessures personnelles, la mort proprietY. suivant, ou du PAR DE peut causer des dommage fi la of Propane Code CSA C22.1 This is the safety-alert FEU, EXPLOSION, EMPOISONNEMENT CARBON DE MONOXYDE, RISQUE DOMMAGE A LA PROPRII_TI_ Cette trousse de conversion doit _tre install_e par un Entrepreneur qualifi_, selon les instructions du fabricant et doff se conformer fi routes les exigences et tout les codes pertinents de l'autorit_ comp_tente. L'Entrepreneur qualifi_ est responsable, et doff s'assurer de bien suivre les instructions dans cet avis. L'installation sera consid_r_ conforme et rencontrant les specifications et instructions du fabriquant qui sont inclus dans la trousse, seulement apr_s v_rification de l'op_ration de la fournaise convertie. signifies hazards which could result in perCAUTION is used to identify unsafe practic- es which may result in minor erty damage. NOTE is used result in enhanced installation, personal injury or product and propto highlight suggestions which will reliability, or operation. []NIT OPERATION Failure to follow components. HAZARD this caution may result in damage to unit 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, Fig. 1). THEY MUST BE REMOVED PRIOR CONVERTING THIS UNIT TO PROPANE GAS. (see TO Table I- Two-Stage Kit Contents ITEM PART Installation Instructions NO. QUANTITY ItKCPLPCONV- 11 1 Propane Gas Orifice #50* LH32RF070 3 Propane Gas Orifice #51 * LH32RF067 3 Propane Gas Orifice #52* LH32RF065 3 Propane Gas Orifice #56" Propane Gas Orifice #54* LH32RF060 3 LH62RF055 3 Propane Gas Orifice #56* LH62RF047 3 Regulator Spring (92-0659) Pressure Switch EF39ZW026 2 HKO2LBO08 1 90 ° Elbow, 1/8 in. NPT CAO5RAO01 2 Nipple, 1/8 in. NPT x 2 in. (51 mm) CA01 CA010 1 Close Pipe Nipple, 1/8 in. NPT x 6/4 in. (19 mm) Wire Harness CA01CAO01 2 48DU400080 1 Propane Conversion Label (Rating Plate) 48VL500206 1 Propane Conversion Label (Installer Responsibility) Propane Conversion Warning Label (Gas Valve) Burner Insert 48VL500207 1 48DU500076 1 48GS5004651 6 • Refer to Table 4 to determine the correct orifice to use. Firing Tube ELECTRICALSHOCK Failure to follow iniury or death. Before NOx Baffle A01051 Fig. 1 - Low NOx Baffle installing HAZARD this warning or servicing PERSONAL INJURY this warning could result in personal instructions cover NOTE: KIT INTRODUCTION the installation of a propane gas combination automatic This Two-Stage 40,000 kit is applicable to 130,000 Btu/hr to units with heating installed at high altitudes inputs from from 2001 ft (610m) to 6000 ft (1829 m). It cannot be used for standard altitude installation. Standard altitude conversion (0-2001 ft) (0-610 m) must use kit CPLPCONV013A00. TWO-STAGE KIT INSTALLATION ELECTRICAL Failure to follow this warning injury, death or property damage. could HAZARD result in personal Gas supply MUST be shut off before disconnecting electrical power and proceeding with conversion. wire from the flame sensor. the brown wire from the burner Save screw. slide out the entire burner the inlet of the heat exchanger rack assembly from 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, exchanger tubes. IMPORTANT: back to natural 11. Using EXPLOSION, cable from the sparker. the screw securing If it if necessary, is expected to remove from the heat that this unit will be converted gas at a later time, these baffles should for reuse. Otherwise FIRE, sparker white flame sensor wires wires from the rollout see Fig. 8. orange 8. Remove and green/yellow violet switch, 6. Disconnect 10. Inspect AND USAGE brown and remove 7. Disconnect 9. Completely unit. gas valve regulator. DESCRIPTION To locate rollout assembly. conversion kit on models 48DT, 48DU, 48XL, 48XT, 577B, 577D, 677B and 677D that are equipped with a White Rodgers 2-stage the gray, blue, from the gas valve switch. stage and low stage. These the screw attaching the gas manifold to the and partially slide out the entire burner rack from unit. Save screw. 5. Disconnect 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 first, then power to unit. the gas pipe from the gas valve. 4. Remove basepan, assembly HAZARD injury or death. TWO-STAGE turn off main the front access panel from unit. 3. Disconnect to follow always in personal Location 1. Turn off gas supply Failure system, result power to system. There may be more than one disconnect switch. Tag disconnect switch with suitable warning label. 2. Remove EXPLOSION, could be retained the baffles may be discarded. a 5/16 in. nut driver, remove the manifold/gas valve Save these screws. 12. For 2-Stage 40,000 Remove the burners assembly the four screws securing to the burner assembly. Btu/hr and 60,000 Btu/hr models only! from the rack, save the screws. Remove the snap ring from the end of each burner. Install burner insert in the end of each burner with the flat sides of the square retain vertical burner and insert horizontal. Replace (See 2 for Fig. the snap correct ring orientation). to Replace theburners in therackusingthesaved screws, making sure closed crossovers ofburners areateach end. 13.Remove thenatural gasorifices fromthemanifold usinga 9/16in.wrench andinstallthecorrect propane gasorifices in themanifold (SeeTable 4 toselect correct orificesize basedon ratedinput.SeeFig.3 and6 for orifice installation). 14.Replace themanifold/gas valveassembly intotheburner assembly using thefourscrews saved fromitem11. 15.Remove theplugontheinletendofthegasvalve usinga 3/16in.hexwrench. 16.Install the1/8in.NPTx3/4in.(19ram)close pipenipple where theplugwasremoved (see Fig.9).Usepipethread dope ortape (field-supplied, nmst becertified forusewith propane gas)foralljoints,making surenotto getany excess inthepipeorvalve. Next,installa1/8in.elbow, a 1/8in.NPTx 3/4in.(19ram)close pipenipple, 1/8in. elbow, 1/8in.x NPT2 in.(51ram)nipple, andalowgas pressure switch asshown inFig.9. 17.Remove regulator cover screws forbothhighandlowstage gasregulators (see Fig.2).Save regulator cover screws. wires to (M). Connect the brown and green/yellow wires to (C). 28, Reconnect the brown wire from the burner assembly to the sheet metal partition. 29, 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 burner rack to the base pan removed in step 4, 30, Remove the connect 1/8 in. pipe a pressure plug manometer on the gas the manifold and (see Fig. 4). J _., ..........ST,C .... STSC_W ON/OFF SWITCH (Propane - White, Nmural - Silver) 1/2" NPT INLET 0 22IN 0 [5 lOIN 5MM] [/8 2MMI ORIFI( 1/2" NPT OUTLET -- FLAME SENSOR -- IGNITOR _ A07804 Fig. 2 - Two-Stage 18. Using a screwdriver, Gas Valve remove plastic adjust screws from both 1 high and low stage gas regulators adjust screws. 19. Remove regulator springs (silver) from stage gas regulators (see Fig. 2). Discard both high and low regulator springs. 20. Install propane gas regulator springs (white) this kit. One into the low stage gas regulator the high stage gas regulator (see Fig. 2). adjust turn clockwise 22. Install flame sensor, orifice/main relationship prior to completing conversion. Partially slide burner rack assembly into unit. pressure the orange wire switch and connect from the (See Fig. 3.) combustion air it to the orange wire on the low air pressure switch (see Fig. 10). 25. Reconnect the violet wires removed and reinstall the rollout in item 5 to the rollout switch. 26. Reconnect orange sparker cable to sparker and reconnect the white flame sensor wire to the flame sensor. 27. Reconnect valve. the remaining Connect the gray wires removed wires to (HI). in item 5 to the gas Connect Igniter, Flame Sensor, Burner Relationship electrical applications, power Orifice/Main and gas supply the gas pressure to the unit. For nmst not be less than 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 burner 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 switch 8MM MAX] 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, nmst be installed immediately into the low stage gas regulator. 9.5 turns (see Fig. 2). igniter, 24. Disconnect propane screw into the high stage gas regulator. adjust screw turn clockwise 23. Verify 31. Reconnect shipped with and one into 13.5 turns (see Fig. 2). plastic [34 A07889 Fig. 3 - Two-Stage 21. Install plastic 37IN (see Fig. 2). Save plastic the blue 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 exchanger under these system, This normally under normal can cause harm to the heat open switch closes when gas is supplied to gas valve operating pressure. The closed switch completes control circuit. Should occur, the gas pressure switch circuit conditions an interruption or reduction in gas supply at switch drops below low gas pressure setting, and switch opens, Any interruption in control (in which low gas pressure switch is wired) quickly closes gas valve and stops gas flow to burners, Table 2 - Two-Stage Sequence of Operations Inducer Pre-Purge Period: When the inducer motor comes up on high speed, the pressure switch closes, and the Infinity _ ignition control on the furnace board begins a 15 sec pre-purge period. If the pressure switch fails to remain closed, the inducer will remain running. After the pressure switch recloses, the Infinity ignition control will begin a 15 sec pre-purge period. Trial-for-Ignition Sequence: The spark igniter will spark for 3 sec, the main gas valve relay contact closes to energize the gas valve on low stage. After 5 sec, the 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 flame-proving sensor, the furnace control determines what heating stage to run based on feedback from the User Interface (UI). If the UI is asking for low stage gas heat, the ignition control will change the inducer speed to low speed and keep the gas valve energized on low stage. If the UI is asking for high stage gas heat, the ignition control will maintain running the inducer on high speed and energize the gas valve's high stage relay to increase gas flow. Table NAMEPLATE 3 - Two-Stage Rated Heating Input, Propane Gas (2001-6000 ft [610-1829 RATED HEATING HIGH STAGE INPU% HIGH STAGE (BTU/HR) m] Altitude) INPUT PROPANE (BTU/HR) LOW STAGE 40,000 38,000 26,000 60,000 57,000 39,000 90,000 79,000 58,500 115,000 103,000 75,000 130,000 116,000 84,500 FIRE AND EXPLOSION HAZARD Failure to follow this warning iniury and/or property damage. could result in personal 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. 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. MANIFOLD PIPE PLUG 099019 Fig. 4 - Two-Stage Burner Assembly BURNER FLAME (Blue in appearance) BURNER MANIFOLD 32. Fire unit and verify proper ignition and proper sequence of operation (Table 2). See Table 4 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 3 for required rated heating input rates. Replace regulator cover screws when finished (see Fig. 2). 33. With burner 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 Fig. 5). 34. Turn off unit, remove pressure manometer and replace the 1/8 in. pipe fitting on the gas manifold (see Fig. 4). 35. Attach warning label (P/N 48DU500076) to visible side of gas valve. 36. Attach conversion label (P/N 48VL500206) rating plate on exterior of unit. above unit C99021 Fig. 5 - Monoport Burner 37. Attach completed conversion responsibility label (see Fig. 7, P/N 48VL500207) inside service access panel. IMPORTANT: Restart including the main manifold pipe plug. unit and leak check service connection, all gas connections gas valve, gas spuds, 38. After all leaks are eliminated, EXPLOSION, FIRE AND EXPLOSION Failure to follow this warning injury and/or property damage. could PERSONAL Failure to follow injury or death. HAZARD result in personal 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. replace service panel. and INJURY this warning could HAZARD result in personal This unit is designed to operate at a minimum 10.0 IN. W.C. of manifold pressure with propane gas. Refer to Table 4 for proper manifold pressure settings. BURNER (3) FLAME SENSOR MANIFOLD ORIFICE (3) TWO-STAGE90,000 BTUHTO 130,000 BTUH UNITS A08565 BURNER INSERT (3) .... .\ \ r _. i ORIENTATION OF BURNER INSERT FLAME SENSOR (3) BURNER (3) _ "__ORIFICE SPARKER - GASVALVE (3) TWO-STAGE 60,000 BTUH UNITS ORIENTATION OF BURNER INSERT I /_ PIPE BURN ER RACK PLUG ORiFiCE (2) TWO-STAGE 40,000 BTUH UNITS A08509 Fig. 6 - Two-Stage Orifice Installation Table PROPANE 4 - Propane Gas Orifice CONVERSION KiT Sizes and Manifold RATING Pressures PLATE (IN. W.C.) CARRIER CORP. TH S APPL ANCE HAS BEEN CONVERTED TO USE PROPANE GAS FOR FUEL REFER TO K T NSTRUCT ONE FOR CONVERS ON PROCEDURES USE PARTS SUPPLIED BY CARRIER CORPORATION AND iNSTALLED BY QUALiFiED PERSONNEL. SEE EXiSTiNG RATING PLATE FOR APPLIANCE MODEL NO. AND iNPUT RATING, NOTE: Gas derated input by 4% for KK,TTNO. rate on each rating 1000 plate ft. is for (305m) above installations sea up to 2000 in Canada ft. the BiOta) input above rating CC;L;cCoONVoO_3Ao000 l_O_.O(O.'(_m_;_;v_a_Tse_)aievel " sea must ) MODELS 48DU 48DT 48XL 48XT .... 577B, 577D, 677B, 677D 48ES 48EZ 48VL 48VT 574D ..... 5770 674D 6770 PY3G 48DU, 48DT, 48XL, 48XT, I I I I I 577B 577D 677B 677D 48ES, 48EZ, 48VL, 48VT, 574D ....... 577C, 674D, 677C, PY3G 48ES, 48EZ, 48VL, 48VT, 574D, 577C, 674D, 677C, PY3G _U,UOU Orifce ManiTold I High / Orifice I ...... Manlro a ! High / O[if ce No Press. Low No • Hress Low No I i 677B I 677D 5770 I I Oto2000ft (0to610m) 55 altitudes ft. above to tFT, m It. (610 to 610m ABOVE SEA 11.0-13.0 in. wc 11.0/5.0 56 I 10.7/4.8 56 I ! I 1O.0/NA 55 ! I 11.O/NA 56 ! I 11.O/NA 56 ! I 11.0/NA 56 I I 11.0/6.0 54 11.0/5.5 54 ll.O/NA 54 11.O/NA I I ll.0/NA 54 11.0/NA MO[ifoi_de pNrO_s High / Low" 53 10.0/5.4 I 54 11.0/6.4 I 54 11.0/5.9 115 ODD ' uaOn_ifi_e9N°_s" High / Low 51 10.0/5.4 115 ODD ' ...... I MaOn_ifoi_d e N°_s I High / Low" I orifice No. I 51 1O.0/NA 49 I I I 52 11.0/5.0 I 52 11.0/NA 50 I I 52 10.6/4.8 52 1O.6/NA 51 11.0/5.0 54 ! I t I I 11.014.9 11.015.2 I MO[i_de NO_s I High / Low" ! 49 1O.O/NA 50 11"O/NA! 51 11"O/NA! 52 11.O/NA NA CONVERTI LE (JOUR I I - 53 11.0/5.5 53 11.O/NA 52 11.015.0 ! NOT APPLICABLE ON - YEAR) ! 53 11.0/NA 52 11.014.8 ll.O/NA 54 11.O/NA 54 11.0/5.0 53 11.0/6.1 10.015.4 I I 54 11.0/5.4 I 10.7/NA 56 10.7/4.8 54 11.O/NA 54 11.O/NA PLroew ss" TO PROPANE GAS level. ! I CE GFiNI_RATEURD'AIR CHAUD A FiTI_ - sea LEVEL} U,S,A, THIS FURNACE WAS CONVERTED - be above 11.0/5.5 56 1 For Canadian Installations from 2000 to 4500 ft. (610 to 1372 m) use U.S.A. column 2001 to 3000 ft. (611 to 914m) (DAY - MONTH must 1372m) 5001to 6000ft. i io_ttogt4mll(gt_to_2t9m>l(122Oto1_24ml I (1525 to1829 m) I 56 I 56 I 56 I 56 I I 130 ODD ' 2000 ft. 12001to 3000 ft. 1. 3001to 4000ft. I 4001to 5000 ft. 1O.O/NA 53 1O.O/NA M_ir_°Id/ 4500 ,NLET PRESSURE(min-max)'. iNSTALLATiON U_n_old/ ProewSS. 10.0/5.0 O[_i.ce 2Jo. 53 tou,uuu 48EZ 48VL 48VT 574D 674D, 677C, PY3G OF for of 2000 ! I 48DU, 48DT, 48XL, 48XT, 577B, 577D, eZZB, e77D 577D rating altitudes 11.0/6.0 56 90 ODD ' 577B input I I 48DU, 48DT, 48XL, 48XT, 577B, 577D, 677B, 677D I the 10% for 10.0/5.0 55 w_n_om/ _wSS. i . Od.fice No I MamTolo wress High / Low" 48ES, 48EZ, 48Vh, 48VT, 574D, 5770, 674D, 677C, PY3G 48DU, 48DT, 48XL, 48XT, by I I eu,uuu ..... _U UUU ' I in U.S.A. be derated ALTITUDE HIGHSTAGE' (Btu/hr) I 40 ODD ' .... 40 0O0 ' - .... level, FUEL USED: PROPANE GAS _EPLATEINPUT, APPLIANCE 48ES level, 52 11.O/NA 48VL500205 POUR - MOIS - ANNEE) DEL'ENSEMBLE N°: KITNO.:CPLPCONV013A00 (0~2000ft.(0~610m) CPLPCONV013A00 (0~ 2000ft.(0-610rn)abovesealevel), CPLPC0NV014A00 (2001~6000ft.(611~1829m) abovesealevel) CPLPCONV014A00 (2001~6000ft.(611~1829m) abovesealevel) BY: PAR: (Name and address of organization making this conversion), which accepts the responsibilily that this conversion has been properly made, (nomet adresse de I'organisme qui a effectue la conversion), qui accepte I' entriere responsabilite de la conversion. 48VL500207 / A08491 Fig. 7 - Conversion Responsibility Label SWITCH BURNER BRACKET C00150 Fig. 8 - Two-Stage Burner Bracket TWO -STAGE GAS VALVE 1/8 NPTx 3/4 CLOSE PIPE NIPPLE 1/8 NPTx 3/4 CLOSE PIPE NIPPLE 1/8 ELBOW 1/8 ELBOW 1/8 NPTx2 LOW GAS PRESSURE NIPPLE SWITCH A06488B Fig. 9 - Installing FURNACE Elbows, Nipples, CONTROL and Pressure Switch on Two-Stage Units BOARD PLUG P1 1 2345678 c, YEL ORN -_ ORN _-- LEGEND ORN = ORANGE YEL = YELLOW LGPS = LOW GAS PRESSURE SWITCH CAPS = COMBUSTION AIR PRESSURE • SWITCH = QUICK CONNECTION A06487 Fig. 10 - Pressure Table Switch Wiring 5 - Single-Stage ITEM Installation Instructions Kit Units Contents PART NO. IIKCPLPCONV-11 QUANTITY 1 Propane Gas Orifice #50* LH32RF070 3 Propane Gas Orifice #51 * LH32RF067 3 Propane Gas Orifice #52* LH32RF065 3 Propane Gas Orifice #53* LH32RF060 LH32RF055 3 3 LH32RF047 3 EF39ZW023 1 Propane Gas Orifice #54* Propane Gas Orifice #56* Regulator Spring (92-0659) Pressure Switch HK02LB008 1 90 ° Elbow, 1/8 in. NPT CA05RA001 2 Nipple, 1/8 in. NPT x 2 in. (51 mm) CA01CA010 CA01CA001 1 2 48DU400080 1 48VL500206 1 48VL500207 1 48DU500076 1 Close Pipe Nipple, Propane Propane for Two-Stage 1/8 in. NPT x 3/4 in. (19 mm) Wire Harness Conversion Conversion Label (Rating Plate) Label (Installer Responsibility) Propane Conversion Warning Label (Gas Valve) • Refer to Table 4 to determine the correct orifice to use. SINGLE-STAGE These instructions KIT cover the INTRODUCTION installation of a 11. Using propane gas conversion kit on models 48ES, 48EZ, 48VL, 48VT, 574D, 577C, 674D, 677C and PY3G that are equipped with a White Rodgers single-stage automatic This single-stage 12. Remove AND kit is applicable Btu/hr USAGE to units with heating installed 40,000 to 130,000 (610m) altitude to 6000 fl, (1829 m), They cannot be used installation, Standard altitude conversion (0-610 m) must use kit CPLPCONV013A00, SINGLE-STAGE at high altitudes KIT the natural gas orifices inputs from from 2001 fl EXPLOSION, for standard (0-2001 fl) INSTALLATION ELECTRICAL Failure to follow this warning iniury, death or property damage. result the manifold/gas assembly valve in personal 16. Remove regulator cover Fig. 11). Save regulator Before installing HAZARD or servicing could system, result always in personal turn off main power to system. There may be more than one disconnect switch. Tag disconnect switch with suitable warning label. 1. Turn off gas supply 2. Remove a screwdriver, the basepan, assembly screw attaching 5. Disconnect and remove To locate rollout screw from sparker 7. Disconnect yellow flame sensor the screw securing the gas regulator (see cover screw. remove the plastic regulator adjust (see Fig. 11). Save plastic reg- 19. Install propane gas regulator this kit. (See Fig. 11). spring shipped with 20. Install into regulator, turn plastic adjust screw (white) the gas 13.5 turns (see Fig. 11). igniter, ignitor, flame sensor, manifold entire to the burner rack gas pressure quick-connect switch (LGPS) equipped terminal. The low should have one unconnected Connect this wire to the vacant orifice/main burner air pressure with a 1/4 in. male gas pressure switch orange wire remaining. terminal on the combustion switch (see Fig. 19). cable from the sparker. PLASTIC wire from the flame sensor. the brown wire from the burner Save screw. 9. Completely unit. and a low gas switch, see Fig. 17. orange assembly. (see Fig. 18). Use pipe thread must be certified for use with making sure not to get any 22. Disconnect the orange wire from the combustion air pressure switch and connect it to the orange wire on the low the gray and brown wires from the gas valve blue wires from the rollout switch. 6. Disconnect 8. Remove gas the using a relationship prior to completing conversion. (See Fig. 12.) Partially slide burner rack assembly into unit. to unit. the and partially slide out from unit. Save screw. the burner (see 21. Verify the gas pipe from the gas valve. 4. Remove into 18. Remove regulator spring (silver) from the gas regulator Fig. 11. Discard regulator spring. clockwise the front access panel from unit. 3. Disconnect NOTE: first, then power using a from item 11. elbow, 1/8 in. x NPT 2 in. (51 mm) nipple, pressure switch as shown in Fig. 18. screw from the gas regulator ulator adjust screw. this warning assembly using the four screws saved 14. Remove the plug on the inlet end of the gas valve 3/16 in. hex wrench. 17. Using Failure to follow injury or death. the manifold 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. Gas supply MUST be shut off before disconnecting electrical power and proceeding with conversion. ELECTRICALSHOCK from assembly. 15. Install the 1/8 in. NPT x 3/4 in. (19 mm) close pipe nipple HAZARD could to the burner installation). 13. Replace where the plug was removed dope or tape (field-supplied, propane gas) for all joints, FIRE, the four screws securing assembly 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. 12 and 15 for orifice gas valve regulator. DESCRIPTION a 5/16 in. nut driver, remove the manifold/gas valve Save these screws. slide out the entire burner rack assembly REGULATOR SPRING (PROPANE - WHITE from NATURAL - SILVER) GAS PRESSURE 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. MANIFOLD IMPORTANT: back to natural for reuse. If it is expected that this unit will be converted gas at a later time, these baffles Otherwise the baffles may be discarded. should be retained 1/2' NPT OUTLET _t_" A07808 Fig. 11 - Single-Stage Gas Valve This normally open switch closes when gas is supplied to gas valve under normal operating pressure. The dosed switch completes control circuit. Should an interruption or reduction in gas supply occur, switch the gas pressure at switch drops below low gas pressure setting, and switch opens. Any interruption in control circuit (in which low gas pressure switch gas valve and stops gas flow to burners. FIRE AND EXPLOSION manifold ORIFICE_ 1 5_I [34 unit 23. Reconnect switch Igniter, Flame Sensor, and reinstall the rollout pearance, 25. Reconnect the gray and brown the burner rack assembly to the into base pan. Align burner connect the 1/8 in. pipe a pressure 29. Reconnect plug manometer electrical power on the gas manifold IMPORTANT: including manifold and gas supply A 1/8-in. NPT plugged connection, must be manometer and replace label (P/N 48DU500076) Restart unit the main service to visible 48VL500206) and leak check connection, the (see Fig. 13). side of above unit (see Fig. all gas connections gas valve, gas spuds, pipe plug. and FIRE tapping, installed 6.5 IN. W.C. and closes at not greater Never test commercially the detection and 36. After 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. can cause harm to the AND EXPLOSION HAZARD Failure to follow this warning iniury and/or property damage. accessible for immediately 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 conditions pressure to the unit. For upstream of the gas supply connection to the gas valve downstream of manual equipment shutoff valve. under these system. the same for (see Fig. 13). propane applications, the gas pressure nmst not be less than 11.0 IN. W.C. or greater than 13 IN. W.C. at the unit connection. test gauge (see Fig. 11). 35. Attach completed conversion responsibility label 7, P/N 48VL500207) inside service access panel. 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. 28. Remove of to decrease pressure. Refer heating input rates. Replace 34. Attach conversion label (P/N rating plate on exterior of unit. sheet metal partition. 27. Slide burner sequence (see Fig. 14). 33. Attach warning gas valve. in item 5 to assembly and firing unit. and proper 1/8 in. pipe fitting on the gas manifold the gas valve. wire from gas spuds, before and that the flames are approximately 32. Turn off unit, remove switch. orange sparker cable to sparker and reconnect flame sensor wire to the flame sensor. the brown ignition cover screws when finished each burner in item 5 to the rollout 24. Reconnect the yellow 26. Reconnect proper all gas connections 31. With burner access panel removed, observe unit heating operation. Watch burner flames to see if they are blue in ap- Orifice/Main wires removed an personal gas valve, pipe plug. All leaks must be repaired regulator 8 M MAX] Burner Relationship the blue wires removed result and leak check connection, pressure and counter-clockwise to Table 7 for required rated A07890 Fig. 12 - Single-Stage could operation (Table 6). See Table 4 for proper manifold pressure setting for your unit. Adjust the gas valve setting by turning the plastic adjustment screws clockwise to increase I6NITOR Operation exchanger Restart the main service 30. Fire unit and verify FLAME SENSOR doses for gas leaks with an open flame. Use a available soap solution made specifically for of leaks to check all connections. IMPORTANT: including quickly HAZARD Failure to follow this warning iniury and/or property damage. Never test commercially the detection is wired) heat 10 could result in personal for gas leaks with an open flame. Use a available soap solution made specifically for of leaks to check all connections. all leaks are elinfinated, replace service panel. and 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. 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 for an additional 45 sec (naininmm). Table 7 - Single-Stage NAMEPLATE Rated Heating Input, Propane Gas (2001-6000 INPUT (BTU/HR) ft [610-1829 m] Altitude) RATED HEATING INPUT PROPANE 40,000 38,000 60,000 53,000 90,000 79,000 115,000 103,000 130,000 116,000 (BTU/HR) / Pipe Plug / Manifold A07872 Fig. 13 - Single-Stage Burner 11 Assembly BURNER FLAME (Blue inappearance) BURNER MANIFOLD A07805 Fig. 14 - Monoport J Burner : / / / / Single-Stage 90,000 BTUH to 130,000 BTUH Units Single-Stage 40,000 BTUH to 60,000 BTUH Units A07873 Fig. 15 - Single-Stage Orifice 12 Installation Rollout Switch Burner Bracket A07874 Fig. 16 - Single-Stage Burner 13 Bracket LOW GAS PRESSURE SINGLE-STAGE SWITCH \ 1/8 NPTx 2 NIPPLE GAS VALVE ELBOW 1/8 NPTx 3/4 CLOSE PiPE NIPPLE 1/8 NPTx 3/4 CLOSE PIPE NIPPLE A07809 Fig. 17 - Installing FURNACE Elbows, Nipples, and Pressure Switch on Single-Stage Units CONTROLBOARD PLUG J2 1 2345678 c, ORN LEGEND ORN = ORANGE YEL= YELLOW LGPS = LOW GAS PRESSURE SWITCH CAPS = COMBUSTION AIR PRESSURE SWITCH • = QUICK CONNECTION A07806 Fig. 18 - Pressure Copyright 2008 CAC / BDP • Manufacturer reserves 7310 W. Morris St. • the right to change, Indianapolis, IN 46231 at any time, specifications Switch Wiring Printed in U,S,A, and designs without for Single-Stage Edition notice and without 14 Units 10/08 Catalog obligations, Replaces: Date: No: IIKCPLPCONV-11 IIKCPLPCONV- 09